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Aussie sheds

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Aussie sheds

Postby uzz32soarer » Tue Jul 25, 2017 5:57 pm

G'day from downunder you blokes.

I'm building a couple of sheds on my farm and thought you might be interested. I'm a self taught welder, having grown up welding on a 180amp 240v copper core arc welder. I used it to build all sorts of things, ultimately a lovely tandem car trailer to move my show cars around.

And then the wife bought me a Mig! And life changed. No ore cleaning up slag. The wire brush retailers all miss me now and she's not plucking bits of wire out of my clothes!

The two sheds are 10mx 9m and 32m x 17m in size. That's about 1000 sq/ft and 5500 sq/ft for you Americans. I designed the sheds myself, had the drawings certified by an engineer and then went and purchased about 13 metric tons of steel to build the frames.

I started on the small shed frames which were fabricated from 50x150x5mm rolled hollow section steel (RHS) with the purlin and girt cleats out of mostly 75x10 and 75x8mm flat steel.

The 240v 250amp inverter Mig did a beautiful job on all of this material but I was running at mostly full whack so that left me bothered when I started looking at the big shed and the size of that material.

So I went and purchased a 15 year oldWIA copper core 335amp 415v Mig from a defunct manufacturing company. I fully serviced it, new bezel, tips etc and started to learn the tips and tricks to the more powerful welder.

I built a sturdy girder trolley to allow me to handle the 8.6m long rafters. Here's a shot of the girder trolley and the two Mig machines.
Attachments
brackets.jpg
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Re: Aussie sheds

Postby weldin mike 27 » Wed Jul 26, 2017 2:54 am

G'day there are about a dozen Aussies here already, My self included. More the merrier as they say. Looking forward to your stories, that's a fairly decent amount of work you have lined up.
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Re: Aussie sheds

Postby uzz32soarer » Wed Jul 26, 2017 6:09 am

Thanks Mike.

I'll throw up a few pictures so you blokes get an idea of what I'm building.

Here's the formwork coming together for the two shed slabs. It took me most of a year to excavate, prepare the area, stone compacted base, steel reinforcing, formwork, boxing etc. All on my own.
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Boxing 03.jpg
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Boxing 02.jpg
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Re: Aussie sheds

Postby uzz32soarer » Wed Jul 26, 2017 6:11 am

Once the concrete was done, then it was time to order the steel.

250UB32 for the columns and rafters, and 50x150x5 RHS fr the smaller shed.
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Steel arrives 02.jpg
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Re: Aussie sheds

Postby uzz32soarer » Wed Jul 26, 2017 6:16 am

After deliberating for about five minutes, I made the executive decision to prepare individual CAD drawings of each separate component and send them off to a plasma cutter to create. Two weeks later, 2 1/2 ton and 1003 components arrived.

Also another 7 ton and 1300 lineal meters of purlins and girts arrived.
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Purlins.jpg
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Plates 3.jpg
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Plates 2.jpg
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Plates 1.jpg
Plates 1.jpg (58.88 KiB) Viewed 815 times
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Re: Aussie sheds

Postby uzz32soarer » Wed Jul 26, 2017 6:21 am

So I made a start. First by getting used to the welder, and materials and made up 156 cleats and brackets. Then I got onto the columns and rafters for the small shed. The wife (Suzie) did all of the primer paint and then I sprayed a nice hammertone top coat onto the finished frames.
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Frame 01.jpg
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Frame 02.jpg
Frame 02.jpg (62.39 KiB) Viewed 815 times
Frame 03.jpg
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Paint 1.jpg
Paint 1.jpg (77.03 KiB) Viewed 815 times
Paint 8.jpg
Paint 8.jpg (59.1 KiB) Viewed 815 times
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Re: Aussie sheds

Postby uzz32soarer » Wed Jul 26, 2017 6:26 am

Time to erect the small shed frames.

Made up a 2m jib to extend the forklift from 4.5m to 6.5m which allowed me to bolt up the components on the big slab and then carry them over the road to the small slab and sit them down in position.
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2881.jpg
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2838.jpg
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Re: Aussie sheds

Postby uzz32soarer » Wed Jul 26, 2017 6:28 am

Suzie helping out and a pile of 5.1m 250UB32 for the columns.
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IMG_2955.JPG
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IMG_2947.JPG
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Re: Aussie sheds

Postby uzz32soarer » Wed Jul 26, 2017 6:30 am

So now I'm nearly ready to start on the big shed. Just working my way up to it. I've never welded anything this big before and it is a bit daunting for a first timer. Hence I'm here, scrounging around for tips and tricks to hold plates, stop things from heat warping etc.
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Re: Aussie sheds

Postby Coldman » Wed Jul 26, 2017 7:56 am

You've taken on a huge personal project, kudos. Looking good and you have heaps of equipment at your disposal.

A couple of things to consider:
- have you removed mill scale from steel prior to mig welding?

- have you cut up a sample weld for macro inspection to confirm your procedure is resulting in good penetration (strength of weld)?

- what are the risks of keeping a large origin lpg cylinder in close proximity to mig welding operations?

Food for thought. Thanks for posting.


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