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<title>Log of the Bunker Ranch Observatory</title>
<link>http://www.bunker-ranch.com/~broblog</link>
<description>A Chronicle</description>
<dc:language>en-us</dc:language>
<dc:creator>terry</dc:creator>
<dc:date>2008-08-04T13:53:14-07:00</dc:date>
<admin:generatorAgent rdf:resource="http://nanoblogger.sourceforge.net" />
<item>
<link>http://www.bunker-ranch.com/~broblog/archives/2008/08/04/index.html#e2008-08-04T13_48_22.txt</link>
<title>To the Future</title>
<dc:date>2008-08-04T13:48:22-07:00</dc:date>
<dc:creator>terry</dc:creator>
<dc:subject>Historical entry</dc:subject>
<description><![CDATA[The last big change at the observatory was installation of
<A HREF="http://www.bunker-ranch.com/construction/newfloor.html">
computer-room raised flooring</A> in the observing room.
I was given about 400 square feet (37 squre meters) of flooring;
it wasn't enough to do my entire observing floor, but by installing
some of it, I was able to gain easy access under the floor to run
cabling to the telescope piers,
and get underneath the floor myself, should it become necessary.
<br /><br />
Otherwise, not much changes at the observatory any more;
things are pretty well set up the way they're going to remain.
There are, however, a few things I would still like to accomplish.
<br /><br />
I'd like a desk, or something that passes for one, in the basement.
Ideally, it would have some large work surface where I could lay out charts
or photographs for study.  I could also use another cabinet or two for
equipment storage.
<br /><br />
I have an open rack holding 96 small-parts bins, but I'd really rather
have an enclosed cabinet; that would also more than double the number
of bins.
<br /><br />
The stairway leading from the observing floor to the basement is well made,
but very poorly designed, and is, in fact, rather treacherous.  It
<EM>really</EM> needs to be replaced.  But I keep putting that off, as
what I really want to do is revamp the whole setup to include some sort of
platform lift
so I can more easily move equipment from the basement to the observing
level.  The hoist in the roof was a useful idea, but it runs too fast
(and it leaks oil on the hottest summer days, which can't be good for it).
And while using the rolloff roof itself as a travelling crane works rather
well, it is of course not possible to do that in poor or windy weather.
A lift in the stairwell would make these problems go away.
<br /><br />
The gable ends of the roof really need ventilation fans, to help
mitigate the heat buildup inside the building during the summer.
<br /><br />
The interior walls of the observatory really need to be black (or perhaps
a dark blue), not white.  The roof can stay white; it helps by reflecting
light when the ceiling lights are on, and the roof is rolled off when
observing so it doesn't affect anything at night.
<br /><br />
I need a small wooden cabinet to hold the networking gear upstairs;
the green
lights from the network switch are downright annoying when you're
dark-adapted upstairs at night.
It's also probably Not Good when frost settles onto the
switch on cold winter nights (which is also why the cabinet should
be wood and not metal).
<br /><br />
It would be nice to have a power-recording monitor, so I would know
when and how often the power goes out.  Without knowing this, I might
be surprised by unintended biology experiments in the refrigerator.
<br /><br />
Some of these things will probably get done, and some will not.  Now
that the observatory is up and running (and producing images) the
incentive to change things is greatly reduced!]]></description>
</item>
<item>
<link>http://www.bunker-ranch.com/~broblog/archives/2008/07/30/index.html#e2008-07-30T10_52_18.txt</link>
<title>Fast Forward</title>
<dc:date>2008-07-30T10:52:18-07:00</dc:date>
<dc:creator>terry</dc:creator>
<dc:subject>Historical entry</dc:subject>
<description><![CDATA[A lot has happened at the observatory since the construction phase was
completed in July of 2002.  It's all been a matter of incremental improvement,
though, rather than any giant leaps for mankind.
<br /><br />
Right about the exact same time as the construction was finishing up,
the observatory's major telescope, an
<A HREF="http://www.bunker-ranch.com/images/denny-hypergraph-loaded.jpg">
Astro-Optik Hypergraph</A>, was delivered.
This telescope, which is a Ritchey-Chretien design, rides on an
Astro-Physics 1200GTO mount.
<br /><br />
A couple of years later, a Paramount ME telescope mount was purchased from
Software Bisque.  The intent is to interchange several different optical
systems on this mount.
<br /><br />
Both of these mounts now sit on heavy welded piers constructed by a local
welder.  The piers are made of 10" diameter steel pipe with 1/2" (1.25 cm)
walls, which are filled with ground-up slag from an old copper mine;
they each weigh an estimated 800 lb (360 kg).
<br /><br />
Somewhere along the line, during the construction, the 40-acre (16 hectare)
property was enclosed by a barb-wire fence and a pair of 16-foot (5 meter)
gates.  For those who remember (you know who you are):  building a mile of
fence in the desert is a lot easier than building <EM>any</EM> length of
fence in the Wisconsin woods!
<br /><br />
The roof is
<A HREF="http://www.bunker-ranch.com/construction/roof_movie.html">
now motorized</A>; it rolls with the aid of a 10-hp reversible electric
motor.  That drives a gearing system that pulls a roller chain that is
attached to the roof; the roof carries limit switches to tell the motor
when to stop in each direction.  All of this mechanism is located inside the
building, so there is nothing external exposed to the elements.
<br /><br />
The installation was quite a process -- we spent 14 straight hours on a
July afternoon in 2003 doing the job with an electrician, a welder, and
two helpers.  We weren't ready to test until after dark, and, of course,
the roof stalled halfway open.  This being the middle of the monsoon
season, it then, of course, started to rain.  So we spent a half-hour, with rain
coming into the open building, adjusting the roof mechanism and finally
getting the roof to close.  The rain promptly stopped, so we gave the
roof a final full-on open/close test and declared victory.
<br /><br />
The unique thing about the rolling roof is that there are electrical lines
in the roof for lighting and for powering the hoist that moves heavy gear
between the observing floor and the basement.  The electrification is done
with the aid of an Igus E-Chain, essentially a large plastic roller chain
that is hollow inside;
two electrical cables run inside the chain, which pays out as the roof
rolls off the building and retracts as the roof rolls closed.
<br /><br />
A Tough-Shed was purchased to serve as a wellhouse; it also houses the
transfer switch and breaker panel for a Generac Guardian generator.  As
the years go by, power outages seem to be less frequent than they used to
be, but the generator is there so the roof can be closed even if the
approaching thunderstorm knocks out the utility company power.
<br /><br />
A heat pump was installed for climate control.  Left to its own devices,
the winter temperature in the basement is 54 degrees F (12 C).
The summer temperature is normally 81 degrees F (27 C), though it can hit 82
during hot spells.  So the heat pump doesn't have a hugely difficult task,
though it works pretty hard during the winter for the first couple of days
after I arrive -- it has to heat everything in the basement, including the
concrete block walls, to around 70 degrees F (21 C).  Once there, it maintains
that temperature pretty easily.
<br /><br />
The thermostat for this setup communicates with the heat pump controls
over a 3-wire digital serial bus.  There's an RS-232 computer serial-port
interface wired into the setup, so I could control the heat pump over the
Internet with a bit of software work, if necessary.
<br /><br />
After having a difficult time carrying the dishwasher down the stairs,
we quickly
decided that this plan was Just Not Working Well, especially since that
was the lightest and smallest unit.  So I called in the boom crane
that served us so well during the building construction.  The rolloff
roof came in handy -- we rolled it back, picked up the appliances,
and lowered them down the stairwell to the basement.
<br /><br />
This same procedure worked out well for the 2,500 lb (1150 kg) of metal
library shelving that holds the observatory's book and magazine collection.
I had it all delivered by motor freight directly to the business that
had the boom crane; they brought it out and delivered it directly to the
basement floor.
<br /><br />
The observatory basement has a rack which holds the computers and network
gear; one of those computers serves the BRO web site and the blog you're
reading now.  There is a gigabit fiber-optic cable running upstairs to
the observing level; more network gear up there connects the telescope
mounts and CCD cameras to the computer in the basement that drives them.
This means that the scopes can be operated from the climate-controlled
basement with the lights on and the refrigerator within handy reach!
(This has vastly increased the hours-of-use of the scopes ...)
<br /><br />
After designing some adapters and making the acquaintance of a couple of
good machinists, cameras can now be attached to the telescopes.  Some
images have been taken, and the results
<A HREF="http://www.sunquest.com/toplevel.html">look good</A>.
<br /><br />
Slowly but surely, activity at BRO is shifting from the manufacturing side
to the operational side.]]></description>
</item>
<item>
<link>http://www.bunker-ranch.com/~broblog/archives/2008/07/29/index.html#e2008-07-29T20_02_42.txt</link>
<title>Finishing the Basement</title>
<dc:date>2008-07-29T20:02:42-07:00</dc:date>
<dc:creator>terry</dc:creator>
<dc:subject>Historical entry</dc:subject>
<description><![CDATA[The basement is fitted out now and
<A HREF="http://www.bunker-ranch.com/construction/basement-done.html">
ready to move in</A>!  Now it's time
for bookshelves (I found a web site that sells used library shelving),
furniture (including a couple of nice recliner chairs), and computers
(like the one that's feeding you this blog).
<br /><br />
I recruited a couple of friends and we went down to the observatory to
frame the interior walls of the basement, preparatory to fitting it out
as a living area.  Basically, there are two rooms -- a darkroom that
ultimately became a bedroom, and a bath/laundry.  The kitchen is on
the outside wall of the bath, so most of the plumbing is inside a single
wall.
<br /><br />
After that, the builder came back one last time, to help install the
shower.  It required a concrete-block base with cement board on top
with pads of grout for the shower-stall to sit on (the shower had to
be raised because there was no plumbing inside the floor slab), and
his proven expertise with block and concrete made him the right person
for the job.
<br /><br />
After almost two years of near-constant concern about the observatory, with
a list of things to do seemingly every day, I confess that I let my
concentration lapse when it came to the basement plumbing and electrical.
I failed to do my usual job of thinking about every detail and anticipating
every need.  I can only plead burnout ...
<br /><br />
As a result, I would up with a cheap, low-quality valve for the toilet --
the kind with the oval handle that requires an adjustable pliers to turn
as they age, instead of a nice 1/4-turn valve.  And I got 1-million-turn
gate valves on the water inlet piping instead of high-quality 1/4-turn
ball valves.  The same kind of valves got put on the clothes washer inlets
instead of the really spiffy single-lever dual valve I would have liked.
Basically, instead of good stuff, I got whatever was on his truck.
<br /><br />
And the plumber turned out to be more of a copper-tubing solderer than an
actual plumber.  He failed to put in a drain line for the water heater TP
valve (this is the valve that pops if your water heater goes overpressure;
it's a code requirement that the plumber seemed clueless about),
and didn't install a drain line for the pan beneath the water heater.   
We had to correct these things later on; the result is pretty ugly, but
it's serviceable.
<br /><br />
Fortunately, at the last minute, I thought about putting an anti-hammer
device on the water inlet line -- the plumber didn't even know what that
was, so had it been up to him, there wouldn't be one.  If you've ever been
in a house where the cold-water line bangs when you shut off a tap, you'll
know why an anti-hammer device is a good idea.
<br /><br />
After that fiasco, somebody else did the finish plumbing.  He helped me
correct the problems caused by the rough-in plumber, and did a great job
in finishing the plumbing professionally.
<br /><br />
The electricians that worked on the building were a lot more professional;
they did both what I asked and what needed to be done for code.  The failure
there was entirely my own; I needed to do a much more meticulous job figuring
out where I wanted lighting, outlets, and switches.  There's been a lot of
retrofitting as I get things set up the way I should have done it in the
first place.
<br /><br />
One place this really affected things was in the circuit breaker panels.
Since I started out with such a minimalistic idea of what I wanted, the
installed panel is a lot smaller than it should have been.  Ultimately,
we had to install a second panel at the far end of the basement to 
accommodate the circuitry I wanted.
   
So, of course, I insisted on a larger panel upstairs at the observing
floor -- and naturally, it's less than half full!
<br /><br />
Anyway, despite my ineptitude, and entirely due to the efforts of a
highly-skilled local home repairman, the basement walls were finished,
textured, and painted.  At last, the observatory is ready for extended
stays.  Now if only I had some mounts and some telescopes ...]]></description>
</item>
<item>
<link>http://www.bunker-ranch.com/~broblog/archives/2008/07/29/index.html#e2008-07-29T10_31_36.txt</link>
<title>Observing Floor</title>
<dc:date>2008-07-29T10:31:36-07:00</dc:date>
<dc:creator>terry</dc:creator>
<dc:subject>Historical entry</dc:subject>
<description><![CDATA[The week ending August 24th, 2001, was the last week of heavy construction
at the observatory.  We installed floor joists, laid plywood, and tiled the
<A HREF="http://www.bunker-ranch.com/construction/obs-floor.html">
floor at the observing level</A>
of the building.
<br /><br />
In the intervening 3 weeks since the building exterior was finished, the
stairway was installed, along with a railing to prevent falling down to
the basement floor 12' (3.7 meters) below.  The rolloff roof proved to be
particularly handy for installing the heavy metal stairway and its landing;
we just rolled
back the roof, picked up the items in turn with a boom crane, and lifted
them over the walls and dropped them into place.
<br /><br />
The original plan had been
to install computer-room raised flooring on the observing level,
but 600 square feet
(55.7 square meters) of this flooring, even on the used market, was just
too costly.  It would have been a real pain to install around the
telescope footings, anyway.
<br /><br />
The height difference between the observing floor and the slab is 27" (68 cm);
I thought this would be plenty of space for floor joists while still leaving
room for me to crawl around the floor underneath the joists when necessary.
But the 18' 8" (5.7 meters) span, plus the requirement to support 1000 lb
(450 kg) of rolling weight when swapping telescope piers, meant that the
engineered TJI joists needed to be 18" (46 cm) high.  Subtracting another
inch for the plywood left just an 8" (20 cm) gap between the slab and the TJIs,
something I could not fit into.  But there was nothing to be done about that
<EM>now</EM>.
<br /><br />
So we installed the TJIs, framing around the telescope footings with some
additional support, and then laid 1-1/8" (3 cm) tongue-and-groove plywood
over the top.  We then tiled the floor in a gray mottled tile.
<br /><br />
As it turned out later, the builder would be back for one more day.  But
otherwise, this was it -- his job was done.  The only remaining tasks were
finishing out the basement, with plumbing and electrical work, and some
electrical work upstairs at the observing level.]]></description>
</item>
<item>
<link>http://www.bunker-ranch.com/~broblog/archives/2008/07/27/index.html#e2008-07-27T04_05_02.txt</link>
<title>The Outside is Done!</title>
<dc:date>2008-07-27T04:05:02-07:00</dc:date>
<dc:creator>terry</dc:creator>
<dc:subject>Historical entry</dc:subject>
<description><![CDATA[Monday, July 23rd, 2001, was a bright sunny day at the building site.  The
observatory building was finally beginning to look like, well, an actual
<EM>building</EM>.  The roof trusses were up, the entry door was installed,
a concrete knee wall had been poured around the subfloor slab to match the
height of the stairwell, and we were ready for siding.
<br /><br />
We installed the entry door by welding some steel columns to the building
skeleton and then welding the steel door frame to the columns.  The bottom
of the door was 27" (68 cm) above the subfloor slab; the door looked really
funny hanging high up in the middle of the sidewall.
<br /><br />
After giving it some thought, it was decided not to lay blocks for the
knee wall around the edges of the subfloor.  The spacing between the steel
columns didn't come out to even block lengths, so lots of cutting would
have been required, and it would have taken a couple of days to do.  Further,
it would have taken some effort to get the block wall to work out to the
exact height required.
<br /><br />
Instead, we built some forms in about 2 hours and called in a concrete
truck.  This solved all of the problems in one stroke.  After the weekend,
we stripped the forms and we were ready to finish the outside at last.
<br /><br />
A pickup arrived from Mesa, Arizona, about 275 miles away, with 2,400
lb (1,100 kg) of residential R panel siding, cut to length for the walls
and the roof of the building, plus a wide range of caps and flashings.
Fortunately, my builder knew exactly what to do with all of these pieces,
and the job proceeded apace.
<br /><br />
In a couple of days, the sides were on.  Then,
after a really brutal day in the sun, the roof was finished.  For once,
we could have used some clouds, and even an occasional rain would have
been a welcome break, but it was not to be.  This all-day job was really
tough up there.  The gable ends were sided, and then, finally,
<A HREF="http://www.bunker-ranch.com/construction/exterior-finished.html">
it was done</A>.
<br /><br />
There was, to my surprise, no fanfare, no ticker-tape parade, no visit
from the President -- nothing.  Suddenly, we had a building.
<br /><br />
It seemed like forever, but it was just over two years since we'd bought
the property, and just over a year and a half since we'd started the job
by drilling a well.  It took a year to build the buried basement, and I
really thought it would be another year before the building was up.  But
instead, the above-ground construction took just 3-1/2 months.
<br /><br />
To be sure, there's a lot left to do.  There's no floor in the building
yet.  The basement is just an empty cave, and finishing it out is going
to require a great deal of work.  But there's a real building now!
<br /><br />
One final note:  after this monsoon season, with the building finally
closed in, the rain stopped.  I mean <STRONG>stopped</STRONG>; it almost
didn't rain <EM>at all</EM> for over a year.  After fighting the rain
every inch of the way while constructing the basement and erecting the
building, it just quit.  I guess Mother Nature figured that if she
couldn't make my life difficult, there was no sense in carrying on.
<br /><br />
OK, the building needs a floor now.]]></description>
</item>
<item>
<link>http://www.bunker-ranch.com/~broblog/archives/2008/07/25/index.html#e2008-07-25T14_48_41.txt</link>
<title>A Rolling Roof</title>
<dc:date>2008-07-25T14:48:41-07:00</dc:date>
<dc:creator>terry</dc:creator>
<dc:subject>Historical entry</dc:subject>
<description><![CDATA[My builder, besides being accomplished at pouring concrete and
laying block walls, is also an expert at erecting steel-siding utility
buildings.  This made him a good choice for this job, because those
three areas are 90% of what it took to get this building put up.
<br /><br />
At this stage, I wound up the last few tasks for the building shell.
I found a supplier who was willing to deliver
2,400 lb (1,100 kg) of steel residential R panel
siding some 275 miles to the building site,
and ordered a prehung steel entry door (which I had to transport myself).
The steel siding folks helped out by being <EM>very</EM> knowledgeable
about all of the extra bits and pieces I'd need, like eave soffit pieces,
end caps, ridge caps, corner and door flashings, etc; not to mention several
boxes of screws for the metal frame and the wood trusses.
<br /><br />
The builder carefully stacked the roof trusses into a neatly-aligned pile,
and then used a circular saw to cut lined-up notches in the trusses for
the 2x6s that would run the length of the building and provide support
for the roof panels.  Then the
<A HREF="http://www.bunker-ranch.com/construction/roofrolling.html">
trusses went up with the aid of the boom crane</A>.
<br /><br />
Even <EM>this</EM> wasn't simple; because of the requirement for a couple
of roof-mounted hoists, the trusses could not be evenly spaced, but rather
had to be set out according to a spacing pattern worked out in advance.
I never seemed to manage to be able to do anything in a conventional way.
<br /><br />
But soon, the trusses were up and bolted to the brackets on the roof frame,
the 2x6 cross-members were installed, and we were ready for the siding.]]></description>
</item>
<item>
<link>http://www.bunker-ranch.com/~broblog/archives/2008/07/25/index.html#e2008-07-25T14_17_56.txt</link>
<title>The Skeleton of the Building</title>
<dc:date>2008-07-25T14:17:56-07:00</dc:date>
<dc:creator>terry</dc:creator>
<dc:subject>Historical entry</dc:subject>
<description><![CDATA[Well, it took some coordinating, but the
<A HREF="http://www.bunker-ranch.com/construction/skeleton.html">
skeleton of the building</A>
was finally erected with 3 days of work ending on July 12th.
The builder, the welder, the delivery truck, the boom crane truck,
and I all had to be at the building site on the same day.
Then things started happening rather quickly.
<br /><br />
We bolted the base plates to the observing-floor slab, stairwell top, and
rolloff footers, and then welded the steel columns to them.  Then the boom
crane got involved, hoisting the horizonal members to the top of the columns
for welding.  We added the corner bracing and welded in the 14-gauge box
beams which will serve as purlins; these accept the screws that fasten the
siding to the walls.  Finally, X bracing was installed between a number of
the columns to help keep the sidewalls from racking.
<br /><br />
Left for the final day (after the photo was taken) was building of the base
frame of the roof and installation of the angle iron that will guide the
V-groove wheels on which the roof rolls.
<br /><br />
To my immense relief, every bit of this "observatory frame on a truck" kit
fit perfectly.  It was all rather like building a full-sized building with
parts from a Kenner Hydro-dynamic Building Set (I had one of those, back
in the day; it's still in a closet here somewhere).  Each part was the right
size, dropped into place perfectly, and the whole thing welded together
with ease.
<br /><br />
The one problem we had was with the braces in the corners at the top of the
wall.  I had a local Tucson company cut 6-foot (2 meter) lengths of steel
box beam at 45-degree angles at each end to fit into the corners; it would
then be easy to simply weld them into place (or at least as easy as handling
115-pound (52 kg) pieces of steel at the top of a wall could be).
<br /><br />
Unfortunately, they turned out to be rather less than certain what 45 degrees
was, and missed by quite a ways.  I would have thought this was fairly
unambiguous, but incompetence abounds.
At any rate, this meant that placing the brace flush against
one wall beam made it wildly out of line with the adjacent wall beam; the
best compromise position left a gap of over an inch on each end.
We did the best we
could by adding some scrap pieces of steel; the result isn't pretty, but it is
functional.
<br /><br />
We had to stop work several times during this phase; nobody wanted to be
anywhere near the boom crane or the steel when there was lightning in the
area (and boy, did we have some lighting!).  We were suffering through
yet another month of record rainfall (the third such month of this project).
Some scrap residential siding was used to build a temporary roof over the
stairwell, else we'd have had an underground swimming pool instead of a
basement.
<br /><br />
The end is in sight now, though!]]></description>
</item>
<item>
<link>http://www.bunker-ranch.com/~broblog/archives/2008/07/24/index.html#e2008-07-24T16_26_55.txt</link>
<title>Building Subfloor</title>
<dc:date>2008-07-24T16:26:55-07:00</dc:date>
<dc:creator>terry</dc:creator>
<dc:subject>Historical entry</dc:subject>
<description><![CDATA[A lot more progress was made in May of 2001.  After allowing the telescope
footings to cure for a couple of weeks, the forms were stripped off.  Concrete
caps were poured atop the footings that will hold the steel columns that
support the rolloff roof rack.  And the subfloor for the building that will
house the observing level was poured.
<br /><br />
At the end of this bit of construction, you can finally begin to visualize
<A HREF="http://www.bunker-ranch.com/construction/subfloor.html">
what the building is going to look like</A>.
<br /><br />
One of the mistakes made during the construction was that the access ramp
the excavator used to dig the basement hole was dug in the location where
we were to pour the footings for the telescope piers.  These footings
should have been placed in undisturbed soil.  In order to mitigate this
problem, we had to do a lot of extra work.
<br /><br />
First, when the ramp was filled in, extra time was taken to drive the
heavy equipment over the area as each layer of dirt was dumped in, to
compact the soil as much as was practical.  Now, with the footings poured,
we backfilled the hole surrounding the footings by hand, using a motorized
tamper.  A few shovelfuls of earth were thrown in, wetted down, and then
tamped.  All told, a day and a half was spent doing this; the footings
should be pretty solidly in place.
<br /><br />
Once that was done, we excavated and laid rebar for the subfloor for the
observing building.  Inch-thick slabs of styrofoam were placed around the
two telescope footings so that the subfloor slab would not contact these
footings.  This will isolate the telescopes from building vibrations.
<br /><br />
Simultaneously with the tamping operation, the electrician was out to
install the electrical panel in the basement.  He put in a temporary
double-duplex outlet so we no longer had to run a couple of hundred
feet of extension cords to get electrical power to the building site.
<br /><br />
This was a time of extensive planning work on my part.  The steel frame
of the building would soon be erected on the subfloor slab, but the
vertical members at the north end of the building would be on top of
the stairwell walls 27" (69 cm) above the height of the slab.  Additionally,
the vertical supports of the rolloff rack would be placed on their own
individual footings built on top of the basement roof.
The top of these three sets of columns all had to be exactly level with
one another; the beams on which the roof would roll would sit on top of
the columns.
<br /><br />
First, the steelwork was sized by a structural engineer.  The building
had to withstand 100 mph (160 km/hr) winds without significant flexure.
This isn't as easy as it sounds -- remember that the roof rolls off the
building, so there are no horizontal supports at the top of the walls
to hold the walls together (or apart, as the case may be).
It turned out that the skeleton of the building had to be built with
6" (15 cm) box beams, which have a wall thickness of 1/4" (6 mm).
<br /><br />
I then sat down with a computer-aided drafting program and began to
design the steelwork that would frame the building, rolloff rack, and
roof.  All of this steel had to be cut to exact lengths in Tucson;
we weren't going to be able to do this cutting on site!  And it all
had to go together correctly the first time, or construction would
have to stop.  I spent a lot of time learning to use the program, then
drawing, calculating, and redrawing until I was certain I had everything
exactly right.  This included bracing in the corners at the top of the
walls and at the end of the roof rack to keep the building and the rack
square.
<br /><br />
At the same time, I got the V-groove wheels on which the roof
would roll and designed brackets to attach them to the base of the roof;
then those brackets had to be fabricated.  Then I had to size the angle
iron the wheels would roll on, and make sure that got onto the steel
order, too.
<br /><br />
To keep the roof from blowing
away, C channel would be attached along the top of the building walls and
the bottom of the roof, arranged in an interlocking fashion so the
roof couldn't be lifted away.  That all had to be designed in concert
with the roof eave detail so that everything would fit without interference.
<br /><br />
I also had templates made for the bolt patterns for the baseplates
of each set of steel columns, and get the baseplates made.  They would
be welded to the columns on site.  The templates would also be used to
sink J-bolts into the concrete to bolt the columns down.  You can see
the bolts sticking up out of the slab in the photo.
<br /><br />
I also needed to provide
steel purlins to run horizontally between the columns of the building
skeleton; the building siding would attach to the purlins with screws.
There had to be a supply of steel rod to make cross-bracing for the
steel skeleton, and I had to get an entry door and the steel necessary
to frame it into the building's skeleton.
<br /><br />
One more small detail:  I had four square plates cut to enclose
the ends of the box beams that would form the top of the long walls and
the rolloff roof rack.
<br /><br />
The wood rafters for the building's gable roof also had to be engineered;
in addition to holding up the roof, they had to provide support for hoists
which would be mounted in the ceiling of the observing building to help
assemble and disassemble telescopes, and move telescopes and mounts between
the basement and the observing floor.
<br /><br />
And in my spare time, I needed to find a supplier for the residential steel
siding for the building and the roof.
<br /><br />
As architect and general contractor, no one would be more relieved than
I when the building was finally erected.  Every day there was a list of
things that needed to be done for the observatory project.  One of the
primary problems was that this construction job was 175 miles from the
nearest construction supply store, so I had to make sure there were
enough supplies to keep things moving.  Everything from nuts and bolts
to welding rods and wrenches had to be anticipated, procured, and brought
to the building site.]]></description>
</item>
<item>
<link>http://www.bunker-ranch.com/~broblog/archives/2008/07/23/index.html#e2008-07-23T09_21_41.txt</link>
<title>Above Ground Level at Last</title>
<dc:date>2008-07-23T09:21:41-07:00</dc:date>
<dc:creator>terry</dc:creator>
<dc:subject>Historical entry</dc:subject>
<description><![CDATA[Once we reached ground level, the fortunes of the BRO construction project
seemed to turn, and things proceeded much more quickly.  What follows here
is the result of a 6-day marathon construction session in April/May of 2001.
<br /><br />
The plastic was removed from the basement roof,
and the footings for the rolloff roof rack were built on top of the
basement roof, and the stairwell opening was extended upward to its
final height.
This last was an adventure;
though it was late April, a cold storm had moved in, and it was snowing
atop the nearby Chiricahua Mountains (about 10 miles to the west).  The
wind was blowing so hard that we were seeing flurries from the mountaintop
storm.  At one point, the builder scooped a trowel full of mortar to lay
a block, and the wind blew the mortar off the trowel!
<br /><br />
We coated the basement roof with waterproofing, and laid the plastic back
down to provide additional water protection.  Later, after the mortar
had had time to cure, we also waterproofed the stairwell extension and
the column footings.
<br /><br />
The septic line, water line, and plumbing air vent lines were installed
using the piping we'd thoughtfully put in the walls before filling them.
We also ran the electric line from the power pole into the
basement through a prepunched hole in the block wall.
<br /><br />
The basement was then buried, and two holes were dug in the area where the
basement access ramp used to be; forms were built in these holes for the
two telescope pier footings.  The footings were poured and prepared steel
plates were embedded in the top; the telescope piers would bolt to these
plates.
<br /><br />
By now, the concrete trucks were getting used to finding <EM>this</EM>
construction site.  Each pier footer involved almost 5-1/2 tons (5,000 kg)
of concrete, so it took two trucks.  And
<A HREF="http://www.bunker-ranch.com/construction/images/capclose.jpg">
the steel plates on each footer</A>
weighed 300 lb (135 kg) themselves.
<br /><br />
That was a tough time.  I drove 3 hours back to Tucson at the end
of a construction day to pick up a U-Haul trailer.  Then it was up early
the next day to pick up the rebar cages for the pier footings and haul
them down to the observatory.  That night, after another day of construction,
I drove back to Tucson to
pick up the plates (which weren't yet ready the first day; my own fault
for poor planning),
then left at 3 a. m. to get to BRO at 6 to prepare for the 7 a. m.
arrival of the concrete.
<br /><br />
At the end of all that work, though, an observatory is still
<A HREF="http://www.bunker-ranch.com/construction/obs-level.html">
somewhat hard to visualize</A>.
<br /><br />
It is now one year since the basement hole was dug, but the long struggle
to get the building put up is nearly ended.]]></description>
</item>
<item>
<link>http://www.bunker-ranch.com/~broblog/archives/2008/07/23/index.html#e2008-07-23T09_03_44.txt</link>
<title>Another Long Delay</title>
<dc:date>2008-07-23T09:03:44-07:00</dc:date>
<dc:creator>terry</dc:creator>
<dc:subject>Historical entry</dc:subject>
<description><![CDATA[After a short search, I found a structural engineer to do some calculations
that would size the steel needed to hold up the basement roof.  My own quick
figuring showed that the concrete roof slab would weigh around 50,000 pounds
(23,000 kg), and the weight of the overlying earth would be about 200,000
pounds (90,000 kg).
<br /><br />
We'd poured the concrete slab for the basement floor with thick 4-foot-square
pads at two positions in the center, and smaller pads at each end, to support
4 steel columns that would hold a center beam.  So all of this weight had to
be supported by the 4 walls and the center beam.
<br /><br />
The roof was built essentially exactly like a small highway bridge, with
support at both sides and down the middle, with steel bridge decking laid
across the supports to hold the concrete.  A 7-inch concrete slab would
be poured over that, with rebar supports every 12 inches in both directions.
<br /><br />
The center beam was sized to hold all of this weight with supports every 17
feet, though the beam is actually supported every 13 feet.
<br /><br />
The structural engineer, unfortunately, lost my first set of drawings, and
turned out to have a method of operation where he would never call you, but
rather would wait until you called <EM>him</EM> for a status report.  That's
how I learned that nothing was happening.  So I
got him a second set of drawings, and I didn't get results for several weeks
after that.  The final tally was that it took 4 months to get the figures
I needed.
<br /><br />
It turned out that the beam would need to be a "12W50" I-beam, which means
the web is 12 inches high and the beam weighs 50 pounds per foot (75 kg
per meter).  The basement required a beam length of 40'-4" (12.3 meters).
The beam is about 10 inches (25 cm) wide and the steel is about a half-inch
(1-1/4 cm) thick.
<br /><br />
So I ordered the steel, had the support columns made, and found a trucking
company to haul the I-beam and the 4 steel columns from Tucson to the
BRO site.  We then used a boom truck to
<A HREF="http://www.bunker-ranch.com/construction/images/beam1.jpg">
drop the steel beam in place</A>.
<br /><br />
After that, we drilled holes in the top of the wall and epoxied some bolts
into place.  A steel plate was then fastened to the top of the wall using
these bolts.  The
<A HREF="http://www.bunker-ranch.com/construction/decked-out.html">
steel bridge decking was laid in</A> and welded to the plate
and to the center beam.
<br /><br />
After lacing in the rebar, the
<A HREF="http://www.bunker-ranch.com/construction/images/baseroof_rot.jpg">
roof slab</A> was poured.  In April of 2001, the basement was finally enclosed.
We covered the fresh slab with plastic and waited three weeks for the
concrete to cure slowly, for maximum strength.]]></description>
</item>
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