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Above 1200 Sq/FT "Thisland" - a 50x100 build thread

Wokspaces above 1200 squarefeet.

Psychoholic

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Joined
Aug 3, 2009
Messages
53
Location
Bogart, GA
I finally have enough pictures of the project to start a build thread!

A few months ago I get a call from a friend that bought some land to put 2 shops on that the lot that backs up to theirs was up for sale for a good price. I wasn't really in the market for it but the deal was sound and after 8 years of renting shops I was about ready to stop paying rent to someone else without earning any equity. Did some creative financing to make the money work, got all of the loans and bought the beautiful 3.31 acres of property in Statham GA which we are calling 'Thisland' because of this clip from Firefly.


After that I did a ton of research on what type of building I wanted, what the math worked out to, and opted to do a 50' x 100' x 18' with a 15' x 50' mezzanine cold formed steel building instead of doing red iron. Red iron seems to be the preferred method for really wide spans but a 50' deep building was good with cold form. Plus this seems to be the way the market is heading (and in full honesty - the wait time for a red iron building was 3x what it is for cold form. I'm terribly impatient as a person and I didn't want to be paying for the land for eternity while renting a shop). We are primarily a small part time fabrication shop and we do powder coating (wheels and art mostly) so all of the math worked out and we have a pretty compelling shop floor layout that lets us do the business stuff and have plenty of room to play with our cars and bikes.

Ordered the building from Metal Building Outlet and had a great experience working with them through the design process and I'm happy to pass my contact along if anybody wants it.

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Next up was working with a general contractor and they have been tremendous too. They just both happen to have property that is within one or 2 lots of me and they're also putting up buildings of similar size so we have been able to combine a few things to drive our price down (like having the grading guy hit multiple lots at a time to save money moving the machines around).

If you've never seen a good grading guy work it is really something special to behold. Our driveway is 560' from the street to where the front door of the building will be. He got most of this done in 3 days. I put a GoPro on my truck and drove down it about a week ago.


(my neighbors/GCs both collect old military trucks and actually use them for work)

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So now we have a graded pad. (F150 for scale). The hill to the right of the picture we did need to push out another 10' to meet with my concrete layout plan so I could have my side pad I wanted.

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So here is where we are today. I have gravel down the entire driveway. I have a stop work order in place that should be lifted today (one of the silt fences ripped and we had some pretty heavy rain for about a a week. That has been fixed (plus grass+straw has been put out) and the inspector should be out today to lift the SWO.

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Once the SWO is lifted the concrete dude is ready to come put in the forms. My plumber is ready to rough in as soon as the forms are in. Then 2 different inspections and we're ready to pour concrete! We are doing 4" of 4k psi concrete. Inside the building is done first and and that will be smooth and all the outside concrete (air compressor pads, driveways, side pad) are all brushed. Building is scheduled to be delivered on the 21st of this month but we have to wait for a minimum hardness of 2500 psi before we can begin so that is 28 days from pour from what I hear.

So there ya go - my big shop build in progress.
 
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ConCretin

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Jan 20, 2011
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3,378
Location
Central Maine
Looks like a great build. Congrats. The rule of thumb for concrete strength development is that it achieves 70% of design strength in 7 days, which in your case gets you to 2,800. Keep in mind this is based on test cylinders in a lab - in place strengths will lag a bit but there is probably no need to wait 28 days. A couple weeks is probably plenty. Good luck going forward.

Take a look at my Guide to Floor Slabs in the link below for some additional thoughts as you get ready to place your slab.
 
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Psychoholic

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Joined
Aug 3, 2009
Messages
53
Location
Bogart, GA
Looks like a great build. Congrats. The rule of thumb for concrete strength development is that it achieves 70% of design strength in 7 days, which in your case gets you to 2,800. Keep in mind this is based on test cylinders in a lab - in place strengths will lag a bit but there is probably no need to wait 28 days. A couple weeks is probably plenty. Good luck going forward.

Take a look at my Guide to Floor Slabs in the link below for some additional thoughts as you get ready to place your slab.
That is some damned good information you've posted and answers that great mystery.

One problem we're definitely going to run into is my stupid need to drive my car over from one shop to another. Currently she's sitting with the top end of the motor missing (donated a bunch of parts to another one) because of my big fuel injection build we're doing and having to fabricate parts for. The other problem is that we still have orders coming in and taking the downtime to go put the building up is going to be pretty hard to schedule.
 
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Psychoholic

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Aug 3, 2009
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53
Location
Bogart, GA
What a neat place to own! Looks like a great piece of property also to put a house on!
My wife doesn't really want to move any time soon (we've put a LOT of work into our basement in the last few years and it'd be nice to enjoy it instead of working on it all the time) but when figuring out where to put the shop I wanted to ensure there was enough room to put a house if I decided to sell the property with the shop on it. That's not ruling out that I might put a house on it and rent it out at some point but that's definitely not in the immediate plans.
 
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Psychoholic

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Aug 3, 2009
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Location
Bogart, GA
Took the drone out there the other day and got a few last shots before the concrete forms go in this weekend.


Also had 2 more loads of gravel brought in so the concrete trucks don't murder my driveway.

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Psychoholic

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Aug 3, 2009
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53
Location
Bogart, GA
Concrete forms are in and the pads for the mezzanine and lifts carved out. We are scheduled for pouring on Friday!

Me for perspective in the middle. I'm 6' and 265# if that gives a sense of scale.
 

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Psychoholic

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Bogart, GA
So yesterday was a flurry of activity. Plumbing rough done Monday. Yesterday we had passed both concrete and plumbing inspection and were given the green light to start pouring concrete!IMG_9848.jpgIMG_9834.jpgIMG_9836.jpg

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Pardon the mild rant for a moment.

The window that we were given for the delivery was from 8-10 yesterday morning. I hired my GC to help unload the building. I meet him at his business partner's house (which is maybe a 1/4 mile from my property) and saddle up in one of the skid steers with forks and we drive over (down some pipeline easement roads) and meet up with 2 of his workers that will be aiding in our unloading process. I spend some time doing some general clean up of some areas beside the driveway so we have places to stash the building. Water meter is also installed at this time so we're worried that we're going to be contending with the semi and the water guys working. Nope. The driver doesn't freaking arrive until 1:30!

Normally I would just settle for 'that's the way these things go' except for the fact I'm paying people just to stand around and pull their puds apparently. When he finally gets there he then informs us that he can't get his truck down our driveway because it's too narrow and it's a 53' trailer. We end up at one of my awesome neighbors' property to unload the building (whose driveway is the exact same size with the same width 2 lane road in front of us).

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We start unloading the 32,862# worth of building in bundles. I have what is probably the limit for what the machine I'm using will pick up and the rear end is feeling pretty light as I back up. Well neither my spotter nor I saw the big *** pine tree right behind me that I bump and end up dumping the load of CEE beams on the ground. Thankfully I didn't hurt anything (myself and spotter included) but I was still a bit irritated at this point in the day.

We were going to move the building over to my property today by way of a few gooseneck trailers but since we have something like 9 or 10 concrete trucks rolling through there I definitely don't want to delay them from pouring. I'm about to head out there and watch the splendor unfold and take a bunch of video!
 

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NickH

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Nov 18, 2015
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283
Location
Southern Maine
Wow that's going to be an awesome space, I can't wait to see the concrete work.

I had similar frustrations with my building delivery, but most of it was my poor planning. Long story short, we ended up unloading late in the evening, with my compact tractor, which meant we had to break up the bundles into chunks that the tractor would actually lift.

I was so paranoid about damage to the building and did bang some things up during the unload and stacking/storing process. The good news is, metal buildings are pretty forgiving. Once you start putting things up, the blemishes all but disappear.

Good Luck!
 
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Psychoholic

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Aug 3, 2009
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53
Location
Bogart, GA
I was so paranoid about damage to the building and did bang some things up during the unload and stacking/storing process. The good news is, metal buildings are pretty forgiving. Once you start putting things up, the blemishes all but disappear.

Good Luck!
Fortunately we are a metal working and powder coating shop and this is a working shop in the middle of the woods so I’m not super worried if we scratch a few things. :)

It feels very real right now.
 
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Psychoholic

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Aug 3, 2009
Messages
53
Location
Bogart, GA
So this is just the time lapse of the concrete getting poured yesterday (minus the last 4.5 yards that was poured directly in that corner later). I’m working on a video of the process up to this point but this was cool enough to stand on its own.

Fun fact: There were a total of 103.5 yards of concrete poured yesterday, each yard of mixed concrete weighs 4050#. That means that the foundation without including the rebar and mesh weighs 419,175#.

 
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Psychoholic

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Aug 3, 2009
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53
Location
Bogart, GA
I actually had to Google where Statham is, but then it donned on me that it's just East of Winder. A cool build either way! (y)
Our current shop is actually in Winder, new shop is 18 miles away. I guess 'technically' it's in Bogart but who is counting? :)

This probably sounds dumb but I was legit worried that I wouldn't have any DoorDash options being that far out but when I pulled up the app with the new address there were something like 50 restaurants! Never really occurred to me that we're only 10 minutes from Athens but still in the country-country.
 
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jeepxj

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Mar 2, 2008
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Why keep the rear entrance and comp area separate? will they be enclosed or just pads?

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Psychoholic

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Aug 3, 2009
Messages
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Location
Bogart, GA
Why keep the rear entrance and comp area separate? will they be enclosed or just pads?

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We are building an enclosure around the air compressor(s) and we wanted it mostly in the center of the building for plumbing purposes and to get it closer to the power panel (although now we're not sure where the power is going to land - it was originally in the middle of the building coming in the back but they are bringing it to the front instead.
 
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Psychoholic

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Aug 3, 2009
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Bogart, GA
I think we might have cursed ourselves by getting the pad done in record time (our GC for the first part made a joke that going from 'untouched forest to a poured slab in 5 weeks is absolutely unheard of'. When the building was delivered the driver wouldn't back into our driveway so we had to drop it at a friends house (we share a property line on the back but there woods between us). They are starting their building at the same we are so we had to scramble to get equipment out there and move it to our property buuuuuuut the equipment rental company didn't deliver when they were supposed to initially and we had to rent more equipment at a higher street rate. Lost a few days by having to spend 2 days moving the building and then waiting on the lifts to arrive. We have been crazy fortunate with the weather this past week though and it looks like it will continue for another.

Having said all that we made some pretty good progress last week. I feel like we could have gotten more done but we are obsessive about square/plumb everything so we're putting in a TON of work in this first portal to get it solid and everything else will get that same squareness from it. They put the septic tank really close to the building right in front of where one of the rollup doors was going to go so we're making the call to move it down a bay. There have been a few on-the-fly calls to adjust things. IMG_0084.jpg
 

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LXCam

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Apr 23, 2013
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19,072
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AZ
Gorgeous property and you definitely planned out a very nice shop. It’s also great seeing a project move right along, it seems most of the time here it’s some sad story of delays caused by some kind of fdupidness.

Good luck and congrats!
 
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Psychoholic

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Aug 3, 2009
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53
Location
Bogart, GA
Gorgeous property and you definitely planned out a very nice shop. It’s also great seeing a project move right along, it seems most of the time here it’s some sad story of delays caused by some kind of fdupidness.

Good luck and congrats!
I am stealing that 'f-dupidness' :)

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Might not look like a lot of progress (it's literally 2 of us most days) but we got a bunch done yesterday. After pulling a fresh chalk line between the columns, measuring the center and verifying them all to be square we dropped a laser plumb and the rafter is PERFECT. Like we thought we lost the laser because it went right between the apex braces and couldn't see it. Following that we installed the rest of the roof purlins, knee bracing, and then did all the x-bracing to lock it in. Today hopefully we can get the second portal done and then fly 2 more columns and a set of rafters with purlins. We found a good rhythm and as we solve one problem we know how to continue without discussion or negotiation.
 

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Psychoholic

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Bogart, GA
Still trucking along. We discovered after getting the girts installed on the first portal that we were using the wrong screws and had to go back and correct those. We have a small army of people coming out today to help which should get us pretty far. We have 2 more column/rafter sets to go then we're at the endwall! With said army with any luck we might be hanging some siding tomorrow!

For a sense of scale the second picture is me at almost 6' guiding a column.

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Psychoholic

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Bogart, GA
Morning update time!

We have one more double column/rafter set to fly then we're at the endwall (so we're 29' from the end). When I was cutting one of the apex braces I made a mistake and cut it on the wrong side and ruined it. We're going to end up robbing one of the pieces used to put in the endwall roll up door to make a new apex brace so I can get it up in the air and set. Today is unfortunately the last day I can fully dedicate to this until next weekend as I have to get back to my actual job. I know my wife is tired of me being gone all the time (and I've gotten really quite used to working from home all the time so being gone for every day for almost 2 straight weeks I really miss spending time with my wife).

We have another big crew of folks out there today who don't know what they are doing so I suspect I'll be directing traffic more than flying around in the boom lift. Now I need to find a way to afford to pay someone else to put up the siding once the structure is done.

Let's hope tomorrow's update is of one big damned building fully framed. With any luck I can have some of my laborers putting up girts and framing in doors.

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Psychoholic

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Bogart, GA
We screwed up big time and it's going to take some real time and effort to fix. I'm back at my actual job today so this will probably be the last shop build update for a few weeks.

When we did the almost obsessively precise amount of layout of the pad with a transit everything was as square as you'd expect from us (we have a bit of a reputation as a shop). We pulled a chalk line from one edge of the foundation outside wall to the opposite corner. With the measurements in place the line was where the centerline of the outside bolts go into the concrete.

Since there were so few of us working on this and only 2 of us doing the layout I guess we rushed and neglected to do it consistent between us. About half of the columns the bracket is to the line instead of the bolt holes and because of this the column is 1 7/8" inward of where it should be. The rafters are a fixed length and you have all this tension it made the roof bow like crazy and despite the columns being pretty much perfectly square and plumb the rafters took the mistake.

Correct:
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Incorrect:

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The result:

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We are going to have to remove the knee braces from the bad columns, relieve the tension on the columns imparted by the rafters bowing, lift them up, fill the old holes with epoxy or hydraulic cement, then redrill new holes, re-attach everything, then negotiate back to square....
Not the update I wanted to give but we all make mistakes. I'm most irritated that this isn't a mistake we'd generally make and we made it repeatedly but I didn't catch it until a LOT of work was already done.

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Psychoholic

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Aug 3, 2009
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Bogart, GA
Gorgeous property and you definitely planned out a very nice shop. It’s also great seeing a project move right along, it seems most of the time here it’s some sad story of delays caused by some kind of fdupidness.

Good luck and congrats!

Well @LXCam it looks like we had some serious delays caused by f-dupidness after all...
 

Klokwerk

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Jan 1, 2010
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Spokane, WA.
Wow, it's going to be an awesome build....tough luck on the oops. But it's fixable.
Staying tuned for updates!
 
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Psychoholic

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Aug 3, 2009
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Bogart, GA
We are back in business!

Took last week off from work and we spent some quality time back out at the shop. Took us about a day to fix the column screw up and the get the roof level again. Added the end wall, installed all the purlins and girts, started framing in the doors etc...

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Then the rains came and they kept comin. We got as much done as we could last week but had to get to a stopping point. That is when a savior of construction appeared in my life from the ether. One of my shopmates dad's best friend brought his crew out today and they are starting to install the insulation and the sheeting! Not sure how long this next bit is going to take but I feel like these guys are going to make some hellacious progress in a hurry.

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I'll try and get out there in the afternoons and see how the progress is coming and make some updates.

Also you can see my new Kubota L2501! I never realized just how damned useful a tractor is until I had one. Not sure how I lived without one this long.

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cannuck

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Nov 30, 2021
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Rural SK
Watching your build and wishing you all the best. We are doing same size (but a bit more sidewall height as have to accommodate overhead cranes) but running way slow as all 100% DIY from inventing/researching some of the materials, design, etc. Big difference is we have to work around some extreme cold, so insulation value of envelope needs a LOT of attention and $$$ to get right.
 
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Psychoholic

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Aug 3, 2009
Messages
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Bogart, GA
My guess that those guys were going to make hellacious progress might have not been giving them enough credit. Holy **** these dudes work FAST and with great skill.

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They got the entire back wall done in a single day and that was even them getting started a little later because I had to give them the full tour of where we were and some discussions around where additional concrete is getting poured. I will say that it's one thing to stand inside the frame of the building and admire the size of it but it just feels different when there is a wall up. When standing next to an 18' tall and 100' long wall it is actually a bit disorienting because it fills up your entire field of view. Somewhat the exact opposite of standing on the edge of a cliff and looking down somehow.

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The building is actually a really lovely shade of green but given the time of day it was hard to get a picture from the other direction.

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mdim

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May 19, 2008
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This is fantastic. My cold formed building (30x50x14) just showed up last week. So seeing how it all goes together is just great.
 
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Psychoholic

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Aug 3, 2009
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53
Location
Bogart, GA
They made more great progress yesterday. I hadn't finished framing in the person doors on the front of the building yet so they put up some temporary panels to keep the spacing. Went out there last night and installed those as well as finished framing in the roll up door on the right side.

We spent so much time having to figure out every single detail (the plans are TERRIBLE) that it felt like such a slog. Seeing a crew who knows what they are doing is just impressive.

I am positively in love with this color. It's basically my favorite shade of my favorite color which is why I picked it when I ordered the building. The only way it could be better would be if it was metal flake. Probably end up painting the doors in some bass boat metal flake and pinstriping the hell out of them as befitting our general motif.

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Bopbop

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May 25, 2016
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Savannah,Ga
Psychoholic,
I really like the building and the color. The all metal construction will provide you a solid trouble free building for years to come. That Georgia red clay looks good. I have been through that area lots of times.
 
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