Trees to be retained were carefully selected by an arborist beforehand and marked with a ribbon. These will now grow larger because they are no longer competing for light with surrounding trees.
photo by Jan Ronfeld
Then, steel reinforcing rods are placed so they will become embedded in the concrete and lend strength to the foundation. Then, more concrete forms will be placed to form the outer wall of the foundation.
Also at this time, concrete drain pipe is delivered that will become part of the drainage system for rain water that runs off the property. This will be channelled down into the farm pond for use in irrigation.
Only half of the foundation is poured at a time. This is because the concrete forms are rented, and it is less expensive to use fewer of them and use them over once the first half is cured.
You can also see in the second picture where the gap was left in the foundation for the barn's large doorway for drive-in access.
The farm pond that will collect runoff water for irrigation is also
being formed at this time. Here, an excavator rests after shaping the
pond's forebay. This smaller pond allows sediment to settle out of the
water before the water passes into the larger pond to the rear.
The larger pond is already collecting water, but this is due to water seeping in from the water table in the surrounding earth, perhaps joined by a bit of melting snow.
Meanwhile, another company is clearing away a tangle of vines and smaller
trees that were beginning to encroach on the field. The result is a more
regular row of trees lining the roadway, carefully selected by an arborist
for variety, health and other factors. Neighbors along North Brigham Hill
Road now have an uninterrupted vista across the field, and you can once
again see the White's farm from the field.
In the center picture you can see the reinforcing bars being put in place in between the concrete forms. These will end up embedded in the concrete after it is poured.
On the day when the second half of the foundation is to be poured, a truck maneuvers a long boom that will carry the concrete mixture into place. Notice that the foundation has a tent made of plastic sheets around it - a propane heater is used under this tent to keep the concrete warm while it is curing to avoid freezing that would damage the concrete when it is still wet.
Inside the foundation, a wooden framework is erected over which a large plastic tent will be stretched. The propane heater will again be put to work to thaw out the ice and snow inside the structure so more work can be done.
Just outside, a large hole is excavated to hold the grease trap. This large (about 6 feet long) structure is required by town regulations because of the commercial kitchen that will be in the barn. It will keep kitchen grease from flowing out into the town sewer system. We hope we'll remember to clean it out!
On the main foundation, a waterproofing material is glued to the concrete to keep water from seeping into the lower level. With this material in place, the dirt can be pushed back against the foundation wall.
Inside the structure, square wooden forms are put in place to pour concrete pads that will be the footings for support columns. Notice the notches at the top of the foundation wall where the steel beams will sit.
Meanwhile, the pond continues to slowly fill up with natural seepage of
ground and surface water. You can see the barn site in the wooded
area in the upper right side of the picture.
The drainage system is now in place to feed the pond. Where it spills into the pond, a pile of rough stones called "riprap" has been placed to keep the dirt from eroding and slow down the water.
No, the barn isn't finished yet... this is the White's barn across the street!
With the foundation walls complete, steel beams are placed across the top of the concrete walls, supported by steel columns that are seated on concrete pads. This steel structure will help support the "post and beam" timber frame that will be the support structure for the upper two floors.
Of course, older barns would have been constructed entirely of wood, perhaps with a granite foundation. But the use of modern materials for the first floor helps us achieve more clear space in the equipment storage area and reduce cost.
The metal tabs you see protruding from the concrete are attached to the steel underneath, and will be used to secure the timber frame to the rest of the structure. The tabs will be inserted into slots cut in the bottom of each wooden post.
At this time a trench is dug from the barn out to the roadway, underneath where the driveway will be. This trench carries an electrical conduit, a 4 inch water line for the sprinkler system (for fire prevention), and a 2 inch water line for service to the building and for backup for our irrigation well.
Notice the yellow tape that is buried above these lines. It says "Caution, Electric Line Buried Below". A clever idea!
The field that Clark prepared last summer has now been plowed again in
preparation for planting later this month. Meanwhile, back at the
greenhouse at Elmwood Farm in Hopkinton, broccoli, cauliflower and
cabbage seedlings are getting near to the size where they can be
transplanted in the field.
On Wednesday, April 17th the massive wood components of the post and beam frame arrive from Vermont Timber Works on two enormous flatbed trucks. Portions of the stone walls along the road have to be disassembed to allow the trucks to make the turn into the site.
The crew from Vermont Timber Works goes to work building the first section (or "bent", as it is called) of the frame. These are assembled horizontally on the first floor deck, in order to make the work easier.
So this is when all the neighbors get together and hoist the frame into position, right? Well, not exactly... Once the bents are all assembled, a crane comes on site to do the work of guiding the bents into place. Workers at each post carefully position the posts so that the slots on the ends of the posts glide into position over the steel tabs protruding from the floor deck.
When the first bent is in position, a machine that looks like a fork lift with an extended lift arm is used to hold the bent in place as a second bent is brought into position. These are then connected together with other wooden beams to provide stability. When several bents are in place, the structure is stable enough to stand on its own.
The roof timbers, called "purlins", are hoisted into place in groups to save time. Straps are used to temporarily connect them together, then the crane lifts all of them at once for a section. Workers on the roof guide them into place as the crane lowers them.
At the end of the seventh day, the complete structure stands on the landscape in all its magnificence! Some of the beams are as large as 8 by 14 inches. It is quite an experience to stand inside the structure.
Even though it is still early in the New England planting season, volunteers have already begun to plant seedlings of such hardy plants as cabbage, brocolli and cauliflower. Around us, the meadows and forests are beginning to turn green with the advent of spring.
All that is left to complete the walls is to attach the clapboards to the outside, and tape and paint the inside. Note the wood strips attached to part of the foundation wall - these will allow clapboards to be attached to that part of the foundation. The barn looks quite different than it did two weeks ago!
And now, is it real, or is it... concrete??? In a compromise of efficiency, appearance and cost, a finish known as "cultured stone" - actually concrete - is applied to the outside of the exposed foundation wall. With the appearance of a traditional stone foundation, this surface economically conceals the concrete foundation underneath. The underlying concrete foundation will provide the necessary strength and water resistance for a long-lasting and dry lower level.
Inside, the barn takes on the character of a cathedral, with light streaming in to illuminate the exposed beams. On the upper storage level, floor decking is installed to provide a surface to walk on. A metal stairway is installed at this time, too. In the lower level, framing is installed for the mechanical, electrical and communications rooms, as well as the stairwell.
The cabbage continues to grow, but now so do the weeds! Time to get back out in the fields to cultivate!
The focus of the work turns inward now, with carpentry, electrical work and planning for the plumbing and HVAC (Heating, Ventilating and Air Conditioning) system all moving in parallel. The electrical sub-panel for the kitchen is installed, and the wiring is run to individual electrical outlets in the walls.
The floor of the cupola is now in place and, after climbing up a series of ladders, you can see expansive views of the fields and the scenery beyond. Meanwhile, the crops keep growing, and some are even ready for an early harvest!