To avoid these ads, REGISTER NOW!

Something just clicked…..

OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
So the pictures don't look like much, but the holes are about 15' by 15' tapered up to maybe 25' by 25' and they are about 6' deep. The first load of flowable fill was not so flowable, we tried to fix it with the second load, but it really didn't help. I am going to have a bunch of leveling to do, luckily the flowable fill is easy to scrape even after it has cured.










 
To avoid these ads, REGISTER NOW!

nine4gmc

Well-known member
Joined
Mar 24, 2012
Messages
14,357
Location
Dallas
Heavy equipment is awesome, I'd be in trouble with power like that! :3gears:

By "flowable", I'm assuming concrete? My cement/concrete experience is limited to a driveway repair earlier this year. We basically busted out the old, packed the base level and dumped 11 bags of redimix in, then ran the hose on it for a few hours.

Sent from my SM-T230NU using Tapatalk
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
Heavy equipment can be fun, but right now it is beating me to death. Since the machine is older it doesn't have "pilot" controls, so I am moving my upper body constantly, then when digging rock like this, the machine bounces and jounces you more than usual. Basically it hurts to sit in the machine for hours.

The flowable fill is actually a sand based material, it doesn't harden like concrete, you can actually still dig it with a shovel when done. It provides something like 98% compaction, so I don't have to use a compactor and that is the main benefit. It is also about a third of the cost of concrete and if done correctly, needs no manipulation, meaning it is self leveling and fills all the pours and cracks.

I am off to the MIL's house to help out for a while, then I am headed to Dad's to pick up some forms that I may be modifying for use on this job. Rebar has been set to be delivered Tuesday morning at 7AM, so we are on a roll, just how my body can keep up with it!
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
When you have a foundation the is in what they call "normal soil" (almost never happens around here) you would just dig down to the depth you want, then you have "undisturbed soil", basically it would be compacted and stable. When you have almost anything but normal soil, you have to over dig the depth and then compact lifts of gravel to the desired elevation. By using flowable fill I over dig the depth, then use a laser level to make marks at the elevation I want, then just add the flowable fill to bring the bottom up to the proper elevation. I don't have to add gravel and compact it as I go, so it saves a lot of time and backache.

Once this is done, it is also used as a leveling pad to set up my concrete forms and rebar, this also saves a lot of time as I don't have to "scab" in small pieces to fill voids around the bottom of the forms. Although with the one hole that had some issues, I will have to do a bit of manipulating the flowable fill to make things level. Once I get things formed up and the rebar in there, it will be really obvious how much effort is saved by using the flowable fill.

Today I spent the morning mounting flower boxes on the MIL's shed, then helped set up some new quick disconnect hose fittings for her. Then I went to my Dad's and got some older forms he had used for another project, looks like I can modify them fairly easily. We spent the afternoon figuring out (read as arguing with each other) how they should be assembled, I think we came out with a good compromise, but ultimately I am doing it mostly my way because I am going to be the one doing the actually work. So we got all the long 2x6s cut to length and brought all the form sections inside, I need to cut them down to length and then add some more bracing and extra plywood. I want to pour the lower parts of the foundations (known as the pad) either Friday or the following Monday, then I can pour the upper parts (known as the pier) a few days later. Then I can strip all the forms and start backfilling around the bases. Of course it sounds easy, but I also have conduits to install, ground wires to trench, and a drain that needs to be rerouted with new pipe. It is going to be an interesting couple of weeks, I sure hope I can find some help to go to the site with me, I have completely struck out so far.
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
16 hour days at the job site have me not wanting to do anything but sleep when I get home. I have pictures and will update soon, I have not forgotten about you guys.
 

Wanna Ride

Well-known member
Joined
Jul 28, 2010
Messages
2,790
16 hour days at the job site have me not wanting to do anything but sleep when I get home. I have pictures and will update soon, I have not forgotten about you guys.
Cool. Just concerned you hadn't been here in nearly a week. Glad to hear you're ok.
 

Kev442

Well-known member
Joined
Jan 15, 2009
Messages
5,386
Location
Wi
Nothing like a marathon project to show what the real priorities are. I had a 13 hour day myself Tuesday. No breaks, no lunch. It had been a while since I went 26 hours without eating, but on warm busy days, my appetite disappears.
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
I have a few things to do today, but expect an update tonight or tomorrow morning. I have a bunch of pictures. Both foundation pads have been poured, I am contemplating stripping the forms today or tomorrow, but I am beat.
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
I worked on the forms the Saturday after pouring the flowable fill, I also spent 1/2 the day Sunday working on assembling them since I had help, then we finished them up on Monday night.






The last real update left us with the flowable fill. I mentioned that one hole was much better than the other, well it took more than an hour of digging with a trowel to get the forms leveled up, then we had to dig out all the excess fill in the middle of the forms. There was a bit over 4" on one end that had to be removed and tapered to the other side. The better of the two holes was still not perfect, but it took about half the time to level the forms. I did not get any pictures of this process, I took a picture after we started adding the first rebar mat, after that we decided to tie them on the stands so the rebar was at waist level instead of having to bend over the entire time.






After tying the first mat on the stands, we tried to get it in the forms with the excavator, it wouldn't reach the center and the mat weighs over 500 pounds, so we were not going to lift it up and walk it in.




My Brother was helping me out, so he brought his bucket truck and we used that to lift the mats in place, it worked much better than I thought it would. Saved us a lot of back breaking labor.


 

dlcwent

Member Emeritus
Joined
Feb 24, 2014
Messages
8,427
Location
coastal maine
Yep, I don't think you could have "manhandled" that into place. Isn't it great to have equipment. I wish I had some.:sad:

Looks good Strouty. I know you don't have any kids, but do you have any plans for today?
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
Once the first mats were in, we had to add the second mat 6" above that, plus all the vertical bars for the pier section of the foundation. None of these bars are small, the mat is #7 and the verticals are #8 (7/8" and 1" diameter solid bars, rebar is sized by 1/8s of an inch), we got the entire first one completed and got most of the second foundation done. Concrete was scheduled for noon on Friday so we had time to get things perfect in the morning. I also set the schedule so we had 1.5 hours between truck loads, each pour was about 9 yards and they can put 10 on a truck around here.









 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
After all that work, it only takes 15 minutes or so to place the concrete, everything went great, nothing moved or shifted, not even a hint of drama. I love it when it is like that!



 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
No worries, going to have breakfast with my Dad, then cleaning up the rest of the basement at the house. How about you?
 
To avoid these ads, REGISTER NOW!

dlcwent

Member Emeritus
Joined
Feb 24, 2014
Messages
8,427
Location
coastal maine
Throwing a steak on the grill tonight and a few cold beers. Other than that, I will mow the lawn and maybe finish planting the raised beds. I've only got a couple of things left to plant.

Have a great day. Enjoy your breakfast with your dad. I wish I could be doing that.

And nice job on the pour by the way. It looked like a lot of work.
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
Sounds like a nice afternoon for sure. The work was a pain, but that is probably the hardest part, the rest will be much easier, well after I strip the forms, then it will be easier.
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
Sunday afternoon I got the forms all removed, the concrete looks great. Today I helped my Brother on a tree job, looks like I may be helping him the rest of the week. I am going to try and pour the rest of the concrete sometime next week, so I can start the backfilling and compacting. Nothing really to update on the shop end, I do have some pictures of the foundations, but I need to upload them. I may be doing a bit of work tomorrow, so I will try and update things then.
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
Here is the latest update, should have been on Sunday night, but I was a bit overworked. Foundations came out lovely, forms removed and loaded on the trailer. I have brought almost all the sections to the job, bless that $500 trailer I bought last fall.





You guys may laugh at this, but I could not figure out the best way to pull out the rebar I drove into the flowable fill to help keep the forms from moving. I used my 8" Snap On adjustable wrench, it has teeth on it almost like pliers and grabbed the rebar perfectly, a couple of twists while pulling up and they came out!












We did have one casualty, my helper (the GF) moved a rebar stand and didn't tell me, it was too close to the excavator so I never even saw it. I guess I will have to weld it back together at the shop.

 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
Today I was on call for my Brother, ended up doing a bunch of paperwork and making a lot of important phone calls to schedule things for the next few weeks. Then I decided to tackle the anchor bolts, I should have put them inside last fall, but I wasn't thinking about it. Anyways the upper part of the bolts are galvanized, but the lower part that is going to be embedded in the concrete is plain steel. They rusted really good, had to use the torch and a 24" adjustable to move several of them. Twenty-four bolts took almost two hours to free up, done and over with, so I am happy. This weekend I need to assemble the forms and build the top parts, going with an octagon, not sure exactly how I am going to figure out all my cuts, a lot of them are compound and I don't do so well with those. I figure trial and error, leaning on the side of error more often than not.











 

nine4gmc

Well-known member
Joined
Mar 24, 2012
Messages
14,357
Location
Dallas
Trial and error is the basis of everything, it was good speaking to you today and I hope the plan works out as you want it to! Good luck!

Sent from my SM-T230NU using Tapatalk
 

Kev442

Well-known member
Joined
Jan 15, 2009
Messages
5,386
Location
Wi
Very nice work. Using the shop for constructing and fabricating instead of storage has to be feeling pretty good. You stole that trailer at $500. $12-1500 all day long around here. I'm jelly big time.
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
I need to rewire the lights and it needs some brake work. Probably going to do the basic lights and flip it next spring. I need a deck over, those fenders are terrible for forklift loading.
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
Helped my brother on Friday, today I ended up getting help from my Dad and we cut down the forms I just made to fit the top of the piers. Also got the octagon inserts figured out, now I have a bunch of wood to cut up. This morning my Brother came over to the shop and wanted to get the skid winch running, with his motivation and help, I thought why not. Apparently it got water in it and the engine is seized up. I have marvel mystery oil soaking in it now, hopefully I won't have to pull the oil pan off, I only put oil in the exhaust and in the glow plugs, not sure if the injectors will be any better. One more thing on my list, guess I should have covered it like many people suggested. I am about done for the day, going home to have dinner early, first night in a while I will be home before 6.







 
Last edited:
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
The exhaust flapper was mounted too low and had been cracked open just a bit, so we moved it up so it sits where it should. Tomorrow I will cover it with a tarp, going to try and get some more oil into it before I do that. I know it turned over just before Thanksgiving, so who knows when it got the water in it. We took the belt off the water pump/alternator and it spun free, we pulled the hydraulic motor and it spun free, we pulled the starter and it sound free. The engine has a large crank bolt, so I have been using my long 1/2" ratchet on it, I may try a 3/4" drive, but I am not sure if I can get it in there.











 

1/2 Cup

Member Emeritus
Joined
Apr 28, 2012
Messages
19,283
Location
Shepparton. Victoria. Australia
Strouty, I am watching your tower foundation build with interest as it is a little different to what we do out here and there will be some lessons learned for me no doubt.

Out of curiosity and apologies if you have already done so what size and type of tower are you putting up?

Regards
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
One of them is 70' tall and the other is 120' tall both are solid leg triangular design with a 36" cross sectional width (center to center). They are self supporting, so no guy wires.

 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
I need to find a gallon of the marvel mystery oil and a big syringe of sorts. I think I can get more into the glow plug opening that way. Hopefully I can have the engine freed up by the Fourth, that would be a good day to have it done.

I am off to breakfast, then to the shop for more work on the forms. I hope I can get the forms all ready to go today, not sure if I am going to make two trips up there today or just unload the tower sections from the trailer and load the forms. I hate to not take the tower sections, but the forms are much more important right now and another trip is about three hours extra time spent doing something not important.
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
After thinking things through, I decided that I could load up the anchor bolts and templates for the towers and haul the tower sections up to the site. I got the bolts all assembled with the templates, but found one template has a bend in it, so I am going to have to fix it next trip up.



 

nine4gmc

Well-known member
Joined
Mar 24, 2012
Messages
14,357
Location
Dallas
Crazy question here but how do you build a 120' + tower? Do you need a crane that is taller than the tower you're building?

Sent from my SM-T230NU using Tapatalk
 

theoldwizard1

Well-known member
Joined
Feb 22, 2011
Messages
43,100
Location
SE MI
Crazy question here but how do you build a 120' + tower? Do you need a crane that is taller than the tower you're building?
Tower Gin Pole


Ginpole1.gif
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
On this particular tower I am using a crane. When you get over 200' then it becomes economically better to use a ginpole. We have decent sized equipment, but in the grand scheme of things our winches are tiny. I have a friend that owns a big tower company and he has 180' ginpoles.
 
OP
S

Strouty

Well-known member
Joined
Mar 21, 2010
Messages
38,210
Location
Southern Maine
Yup, special design. Each foundation has about 13 yards of concrete and then 100 yards of gravel compacted around them. That is probably upwards of 350 thousand pounds of counterweight. Should be good enough.
 
To avoid these ads, REGISTER NOW!
Top Bottom