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August & September  ...

 

After a 10 week hiatus, we finally got back to work when the sanctuary asbestos was removed.  It took a lot of work to pull all the pieces back together.   We learned a lot about equipment needs, what jobs need to be performed, how to allocate tasks, which methods work or do not, and dealing with vendors of the wide range of local service suppliers and organizations.  Below is the crew and setup that we have found works well.  Scaffolding the same width of a wall, four men on the platform, two removing stones with hammer drills, and two positioning stones and documenting each stone on a pallet.  Pallets weigh over 2,000 pounds.  Individual stones average 50 pounds. The high lift holds the pallet at the work surface.  This process minimizes the number of times a stone is touched.  Stones are off the wall and in the box.  Work proceeds right to left by rows, and top to bottom of a wall.  Documentation is by highlighted photographs.

 

     

    

    

     Removal of the window frames that held stained glass windows.

 

    

To keep track of the original stone location, each wall is photographed, and as stones are removed, their location is highlighted.  Each picture depicts the stones in a specific pallet.

 

    

Pallets are packed with straw to prevent damage to the stones.  Pallets are then covered in plastic to shelter from weather. 22-24 pallets per truckload.   Finally, each pallet is covered with construction fencing and banded with steel strapping to avoid loss and damage during shipment.  Pallets are numbered to indicate what portion of wall is included, and weighed.  This pallet is the fourth pallet from wall C, weighing 2,215 lbs.

 

    

Finally ... Truckload 1 to Texas   45,000 lbs  -  Middletown, Ohio to Bee Cave, Texas  -  1179 miles

 

    

Frank - Foreman                                                                                               Lee                

 

    

Aaron removing the peak                                                                 The Peak - 3,173 pounds

 

 

Video of the Peak coming down  ... Brian's awesome touch !

 

Corner Stone

    

 

Dick Clark Architecture's Rendering of Revival in Bee Cave, Texas.

September

     

The North Wall with Stone removed   The brick interior wall is not fashioned for strength.

     

Walls can collapse without warning          Location of Porch Pallet # 4        

       

Lintels and capstones are numbered with location .. laminated tags fixed to stones.  Duct Tape labels did not survive trucking.  These tags secured by drilled anchors.    Roof  Trusses connect to Buttresses.    Note large one piece connecting stone.

 


 

  One of the most difficult tasks was to remove the roof.  Composed of several layers of tar paper over very dense wood sheathing.  Removing the 120 individual panels was time consuming and wore out saw blades rapidly.       

 

     

What we start with                                                What we end with

     

     

     

      

We have 120 of these panels to remove.                       William and Pedro                   

 

 

     

The wooden roof structure was complex ...  purlins, beams, and trussess attached to stone buttresses.

         

     

 

          

  


Next came the bell tower.

 

          

 

Now, for the big challenge .. top 20 ft of bell tower

 

     

The first step was to remove all of the decorative stone down to the lintels, then the roof.

 

      

Note the big white stones below brick .. 1,600 lbs apiece .. have 48 of them to remove.

Watch a YouTube video of the roof coming down. Just as we wanted.

 

The building has to be taken down in the right sequence for safety and equipment operational capabilities.  Finally, we have reached the 60 ft bell tower.  The ladder to the right is an escape route if the rotten roof falls with worker up high 

 

           

Bell Tower - At 109 years, the stone shows no sign of wear.  Just as sharp and crisp as in 1904.

    

Now the heavy lifting really begins.

 

   

Hammer Drill to insert lifting points into big stones  Working at tower level, drilling seats for eye bolts

 

    

Eye bolts to D-clasps to lifting straps allow safe heavy pickups                 Stone is removed.

         

         

 

Video of a stone coming down

 

 

     

Rain becomes a problem.  This is a day after a thunderstorm.   Will and Pedro.  The working platform increases mobility and productivity.

 

We are crowded into a tight space.  Frank's passion for order takes over our Mini-Mobile secure gear container.

 

 

     

 

 

    

Foundation Stones ... Building lintels and window stones.    The big stone upper left weighs 1,150 lbs.  So, on a stone that is 53x23x9, weighing 1,150 pounds,  the actual weight of this white Bedford Limestone is 181 lbs per cubic foot.   15 % higher than our original calculations of 160 lb.  This limestone is denser and combined with color, uniformity and shape is of the very finest quality.  

 

        

50 years growth rings equal 1 inch of old growth heartwood

 

The wood is antique old growth southern pine heartwood.  The finest wood available.  300 years old in 1900.

 

 

 

Preliminary architectual drawings.  The orange highlighted areas indicate that we will be short of stone.

 


 

Go to Daily Work - Winter

Go to Daily Work - April

 

Back To Work In Process

History and Current Offerings

 

Electronic mail             Info@ResErections.com

 

 


 

 


HOMERomanesque IVictorianRomanesque IIIRomanesque IVAmerican FolkCotswoldReVivalKemper
ChurchesWork In ProcessReConstructionTerms of SaleQuestions