The Making of Steelhenge

Remember when the container arrived in April with tons of steel beams for the gym construction?
Putting them in place in the gym has been an incredible feat, similar to construction of Stonehenge… at least the end result is a masterpiece of metal monoliths reminiscent of the English monument.

The 14 I-beams that arrived by container in April

Ron discovered that the spacing of the holes at the bases of each beam differed slightly one from another. So plywood templates were made for each one, that served as a guide in creating the foundational pegs into which each beam would fit.

The template with pegs in place and ready for the concrete foundation to be poured

 

foundation for one support beam being successfully poured

In August the foundations for the 2 beams nearest the building structure were ready. Ron decided to put the huge beams in place using equipment we have at school.  They positioned one beam at the base of the foundation lining up the pegs with the holes in the base of the beam.

Support beam lined up next to the foundation pegs

And with the aid of the Kubota’s bucket, wooden poles, and some cable, they lifted the beam and dropped it into the pegs.

Lifting one support beam into place with school equiupment

It only took 3 hours to get each of 2 poles nearest the building in that way. Clearly it was not a good option for the remaining 12 support beams. So, they contacted a local company from whom they could rent a crane. Meanwhile, they kept working at creating the 12 foundations for those beams.

Foundations for support beams down one side of the gym shadowed by the building. Can you see the shadow of the photographer?

October 17 the crane arrived and in one day all 12 remaining beams were installed!

The crane lifted each beam with ease

 

The guys swooped in to guide the holes at the base of the beam into the foundation pegs. See Ron watching in the background? He was pleased 🙂

I must admit, watching the first one made me nervous, so much opportunity for injuries — but the chains, cables, straps all remained intact and machinery functioned properly.

Ron dragged each beam with the Kubota tractor to the appropriate foundation

 

The beams were lifted into place

 

And each one secured to the base

Did I mention October is still rainy season? The construction site has been a giant mud puddle for much of this year! And it had rained all night the night before this historic day. Rain seems to plague all that happens with these beams: the container bringing them got stuck in mud, and the crane putting them up also got stuck! The crane had difficulty getting near the farthest foundation on the 2nd side because of all the mud!

One side done, one side to go. The crane had trouble reaching the farthest foundation

They had to pull the crane out of the mud so it could get in position for the next beam.

Using a chain, the Kubota pulled the crane out of the mud

At the end of the day, all 14 support beams were in place. Nobody got hurt. Praising God for a great success!

Ron looks over the creation he has named “Steelhenge” with gratitude and a deep sense of satisfaction.

The next big challeng will be welding the 3 parts of each of the 14 trusses together and hoisting them on top of these support beams! Prayers for wisdom and continued safety appreciated.

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