What a year 2020 was! In spite of the global pandemic, we made quite a few things happen over the last year. We’d like to take a moment to celebrate some of these accomplishments:
We purchased our first ever BRAND NEW tractor
We doubled the size of our laying flock
We were awarded a grant by the Food Animal Concerns Trust
We constructed a 30’ x 50’ quonset hut all by ourselves
We moved all of our hooved animals into the new barn
We began accepting soap orders directly through our website
We have so much to look forward to in 2021. Here are some of the exciting developments that are to come:
The addition of livestock guardian dogs to our farm
The installation of permanent fencing to provide our goats with approximately six acres of pasture
A brand new raised bed garden
The opening of a new farm-to-table restaurant in Malone that will feature some of our products
Regularly scheduled farm tours
A round pen for exercising our horse
New products at the farmstand (our own and from our local partner farms)
We have several other projects underway but they may not be complete until 2022. We have a lot of work ahead of us, but we believe we are taking our farm in the right direction and that it will all pay off in the future. Stay tuned for updates along the way!
Since our quonset hut is now more than half assembled, I figured it was time to share an update!
We started out doing things the VERY hard way. First, we tried standing up a fully assembled arch, with the help of Brandon’s father and brother. We quickly learned that the arches have a propensity to twist. We abandoned that method before we did serious damage to the building and/or one of us. Next, we began standing up sections of arch by standing on ladders and scaffolding that we strapped into the bed of our truck to gain some additional height (I’m sure this is completely OSHA approved).
Construction wasn’t moving along as quickly as we would have liked, and it was still incredibly challenging to put up a full arch with only two people. With winter looming just a few weeks away, we decided to rent a scissor lift to get the job done.
With the scissor lift, the two of us can assemble an arch in a little over an hour. We’ve developed our own method: we stand up the side pieces (there are two pieces on each side), we bolt the side pieces in place, and then we tie the sides together with the center piece. We made a timelapse video to share on our new YouTube channel. Check it out: https://youtu.be/COXFMZD_jLI
The biggest mistake we made when we ordered our DuroSpan steel building kit was NOT ordering the hand welded base plate along with it. I don’t know what we were thinking. The base plate may not be necessary to install the quonset hut, but it definitely makes it 1,000% easier. Had we ordered the base plate at the same time as the building, we would have saved close to $1,500 in extra freight charges and would have been able to erect the building six weeks earlier. But life is all about learning from your mistakes, right?
Once the base plate arrived, we set to work installing it. First, we laid out all of the sections so that we would know where the holes were. Then, we used a hammer drill (98 times!) to make 3” deep holes in our concrete pad. We coated the bottom of each base plate section with roofing tar to prevent water from seeping underneath the base plate. Finally, we bolted each section in place.
While we were waiting for the base plate to arrive, we started assembling partial arches. (I strongly recommend getting a head start on this if possible; your hands will get tired after putting several together because there are SO MANY BOLTS!) Often, it’s just the two of us working on the barn, so we opted to stand it up in sections as opposed to full arches. I will be sure to post again as we begin erecting the structure.
I’m sure there will be a bit of a learning curve with this next step, ha!
Over the past several weeks we’ve slowly but surely been working to prepare the building site. We started by running mason’s line to determine where to build the forms. We then built the forms using leftover lumber from our sawmill, which involved cutting and driving LOTS of stakes. Once the forms were constructed, we leveled the ground beneath and added fill to make the pad a uniform 4”.
To reinforce the concrete, we laid a grid of remesh, which is similar to panel fencing used for livestock. We set the remesh on 2” patio pavers, so that it would be in the middle of the 4” thick pad. Our barn is 30’x50’, however, we decided that it would be easier to pour the concrete in two sections. We drilled holes in the form boards that divide the two sections, and inserted short pieces of rebar every few feet to tie the two slabs together along the joint.
Finally, on Saturday morning, we had a truck come and pour 10.5 yards of cement. It took our four man crew just under an hour to get it all poured and screeded. We ended up with some extra cement, so we used it to make an apron where the barn doors will be.
Before we can pour the other half, we need to finish the installation of our driven point well (more on that later). We plan to house the well pump in a small, heated room inside the barn where we will also have a slop sink for washing eggs. We are really looking forward to having a water source in the barn, as we have been lugging buckets from the house for the past three winters.
Our DuroSpan steel building kit was delivered this past week! We opted for a classic Quonset hut style building, which is constructed of a series of arches that bolt to one another. Pictured above are the pieces that make up the arches. I’m not going to lie, it’s a bit daunting to see multiple buckets of 600 bolts, knowing that my husband and I are the ones that have to put this whole thing together.
Over the weekend we began working on building forms so that we can have a concrete slab poured. The slab is arguably the most important part of the whole project, as the building draws its strength from being bolted to it. It’s crucial that the concrete is level and that the corners are square, so we are double (and triple) checking every move we make, using line levels and mason string. Once the forms have been completed, we’ll use our tractor to level the ground beneath so that the pad is exactly 4” thick.
Hopefully the cement work will be done soon so that we can get started assembling and erecting the arches!