Building a new shop
From Crankshaft Coalition Wiki
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If you ever thought about building a new shop, this article will help guide you through some of the thought process that goes into planning and building a new shop. | If you ever thought about building a new shop, this article will help guide you through some of the thought process that goes into planning and building a new shop. | ||
| − | All ideas contained in here are subject to the | + | All ideas contained in here are subject to the town planning scheme in your local jurisdiction, as well as climatic and economic conditions of your area. The final choice is totally up to you and your pocketbook. |
==Site selection== | ==Site selection== | ||
So where 'ya going to put it? Grab yourself a survey certificate with a drawing of your property lines in relation to your house location. Couple this up with the building code from your area, which will tell you things like maximum site coverage, distance for side yard clearances, max. heights, etc. Get a piece of graph paper along with a three sided architect's ruler with different scales. Using standard 1/4 inch graph paper, re-draw the lot size along with the structures on the property using the measurements found on the survey drawing. If you start off with a 8 1/2 X 11 inch page, you can then have this blown up at the local Kinko's to a size that you feel more comfortable with. | So where 'ya going to put it? Grab yourself a survey certificate with a drawing of your property lines in relation to your house location. Couple this up with the building code from your area, which will tell you things like maximum site coverage, distance for side yard clearances, max. heights, etc. Get a piece of graph paper along with a three sided architect's ruler with different scales. Using standard 1/4 inch graph paper, re-draw the lot size along with the structures on the property using the measurements found on the survey drawing. If you start off with a 8 1/2 X 11 inch page, you can then have this blown up at the local Kinko's to a size that you feel more comfortable with. | ||
| − | Your next stop is to have the local utilities company come down and stake out the location of existing underground lines for power, gas, water, and phone/cable, and plan the placement of the additional services to the new building. Transfer these measurements to your plot plan drawing and color code each utility to make them distinctive. | + | Your next stop is to have the local utilities company come down and stake out the location of existing underground lines for power, gas, water, and phone/cable, and plan the placement of the additional services to the new building. Most states have a "One Call" phone number that will inform all utility companies. The phone numbers can be found in your local phone book, or by googling "One Call" and your state name. In some states this is mandatory by law, even on your own property. In the event utility locations are done and you were to "hit" a unmarked service, you will not be responsible. Transfer these measurements to your plot plan drawing and color code each utility to make them distinctive. |
Now, you're ready to decide what size structure you need. On a separate sheet of paper, draw out different sizes of buildings using the same scale size as your plot plan, and cut out outlines. Try different outline placements and shapes. If you use heavier construction paper, they will lay flatter and stay in place as you adjust them on your plot plan. You can even draw in existing or future landscape features so that you will be able to look at the total picture of your project. | Now, you're ready to decide what size structure you need. On a separate sheet of paper, draw out different sizes of buildings using the same scale size as your plot plan, and cut out outlines. Try different outline placements and shapes. If you use heavier construction paper, they will lay flatter and stay in place as you adjust them on your plot plan. You can even draw in existing or future landscape features so that you will be able to look at the total picture of your project. | ||
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An outer perimeter of rebar is a must to tie all corners of the slab together. When any openings are encountered, you should double the rebar and thicken the width and depth of the concrete and pour a grade beam to help bear the weight and anchor the side posts of opening to the slab. Wire mesh for re-enforcing the slab should be tied to the perimeter rebar and rebar 'chairs' should lift the rebar to float in the middle of the concrete slab. Do not rely on someone lifting the wire mesh as you are pouring. | An outer perimeter of rebar is a must to tie all corners of the slab together. When any openings are encountered, you should double the rebar and thicken the width and depth of the concrete and pour a grade beam to help bear the weight and anchor the side posts of opening to the slab. Wire mesh for re-enforcing the slab should be tied to the perimeter rebar and rebar 'chairs' should lift the rebar to float in the middle of the concrete slab. Do not rely on someone lifting the wire mesh as you are pouring. | ||
| − | Any electrical conduit should be under the mesh and conduits should be tied to vertical staking to maintain proper heights. In-floor heating lines should be laid in work zones and above the wire mesh. Header pipes should be staked as stated above and all joints in lines should be ABOVE the concrete. | + | Any electrical conduit should be under the mesh, and conduits should be tied to vertical staking to maintain proper heights. In-floor heating lines should be laid in work zones and above the wire mesh. Header pipes should be staked as stated above and all joints in lines should be ABOVE the concrete. Risers should be rigid conduit for mechanical protection but horizontal runs work better in plastic conduit; no galvanic reaction takes place with the cement and if wires go to ground inside the pipe (not likely, but it happens) they won't weld themselves to the inside walls. That means you can always pull them back out. |
| − | Some people prefer a curb around the perimeter of | + | Some people prefer a curb around the perimeter of the building, rather than a slab. The reason for the curb is that it will keep out moisture, insects, etc. When pouring floors, always have a rotating laser level on hand and double check levels as the pour and leveling goes on. Grade floor from corners to middle, and center of space to outdoor openings. Put a sump pit in large buildings to collect runoff water and use a gravity drain or pump out system to remove it. Increase floor thickness in areas where you are using a lift or have heavy shop equipment. |
| − | + | If you are considering a car lift or heavy vehicles, you should plan on a slab thickness of at least 6" rather than 4". Tell the concrete installer that you want a "smooth' floor. Try sweeping rough concrete and then try smooth. You will never want rough again. | |
| − | If you are in a frost zone you should probably inquire about "frost walls." This will keep the outer walls from lifting and cracking with the frost. This is also the time to consider floor drains. Ask the floor installer about it. He should have good ideas and it won't cost that much. | + | If you are in a frost zone you should probably inquire about "frost walls." Frost footings are dictated by code where applicable, typically slab on grade shops or garages over 28' x 28' will require footings, again this is dictated by code and is dependent on typical frost depths in your area. This link is a contour map of the United States showing average frost depths encountered: http://www.soundfootings.com/pdf/US_Map_Frost_DepthAVG.pdf. This will keep the outer walls from lifting and cracking with the frost. This is also the time to consider floor drains. Ask the floor installer about it. He should have good ideas and it won't cost that much. If you are bound by building codes inquire with your building inspections department about drains. |
==Walls and roofs== | ==Walls and roofs== | ||
| − | Eight feet should be the minimum wall height. Ten foot will allow more room for lighting, overhead storage, ventilation, vehicle size, and equipment and its use. Twelve feet is minimum height for using a auto lift. Sixteen feet is minimum if you are planning on a mezzanine for storage and office areas. | + | Eight feet should be the minimum wall height. Ten foot will allow more room for lighting, overhead storage, ventilation, vehicle size, and equipment and its use. Twelve feet is minimum height for using a auto lift. Sixteen feet is minimum if you are planning on a mezzanine for storage and office areas. If your codes prevent you from having a tall roofline for a 12 foot ceiling , you can do a 10 foot wall and use scissor trusses to gain more ceiling height inside the shop or if you have a steep roof you can have them install a cutout area so you can install a lift and have plenty of ceiling height. |
| − | Wall styles will vary from post and beam, standard framing, concrete block and steel. Everyone has an opinion and it is usually the depth of your pockets that dictate what you build. Try and make the walls rhyme in with the decor of the surrounding area. A red barn is quaint but | + | Wall styles will vary from post and beam, standard framing, concrete block and steel. Everyone has an opinion and it is usually the depth of your pockets that dictate what you build. Try and make the walls rhyme in with the decor of the surrounding area. A red barn is quaint, but will look out of place in "Yuppyville". Neighbors tend to complain less if you "blend in". |
| − | If your local code allows it, consider using 2x6 lumber for conventionally-framed structures. It reduces the number of studs (24" | + | If your local code allows it, consider using 2x6 lumber for conventionally-framed structures. It reduces the number of studs (24" O.C. vs 16" O.C.), and allows more insulation in the wall cavities. While possibly more expensive, in the long term, the better insulating capabilities offered will offset the price. |
Roof coverings can be asphalt or fiberglass shingle, steel sheet or wood shakes. Again, it's your pocketbook. Most people should put up the best roof that they can afford because you only want to go up there once. | Roof coverings can be asphalt or fiberglass shingle, steel sheet or wood shakes. Again, it's your pocketbook. Most people should put up the best roof that they can afford because you only want to go up there once. | ||
==Insulation== | ==Insulation== | ||
| − | It really doesn't matter if you live in the colder or hotter part of the country, insulation will benefit either way. Keeping out the heat from a Texas sun or keeping in the heat during a Canadian winter, insulation will do its part in your construction of your building. Insulation will also deaden the noise that you produce in your shop. Remember the last time you used an air chisel to remove that rusted body panel at 11:30 pm? Or the sound of the last thunderstorm that | + | It really doesn't matter if you live in the colder or hotter part of the country, insulation will benefit either way. Keeping out the heat from a Texas sun or keeping in the heat during a Canadian winter, insulation will do its part in your construction of your building. Insulation will also deaden the noise that you produce in your shop. Remember the last time you used an air chisel to remove that rusted body panel at 11:30 pm? Or the sound of the last thunderstorm that passed over your steel roofed shed! Try using as much insulation as you can afford. It will pay you back double or triple over the original cost you invested. Don't forget the vapor barrier, at least 6 mil plastic. Seal the electrical outlet boxes on the outside wall to prevent moisture infiltration into the insulation and wall section. |
==Doors and windows== | ==Doors and windows== | ||
Window are supposed to provide you with light and ventilation. There are many styles of windows to choose from; find something that compliments the style of your home and climatic conditions. Triple pane windows with low E glass act just like insulation and will pay a return over the years. Roof skylights and ridge vents are excellent in larger shops for bringing in light to the center of the building. | Window are supposed to provide you with light and ventilation. There are many styles of windows to choose from; find something that compliments the style of your home and climatic conditions. Triple pane windows with low E glass act just like insulation and will pay a return over the years. Roof skylights and ridge vents are excellent in larger shops for bringing in light to the center of the building. | ||
| − | For every opening you make in a building, you are losing a bit of security. One option is to use 7/16" OSB to clad | + | For every opening you make in a building, you are losing a bit of security. One option is to use 7/16" OSB to clad inside walls. You can cover the whole wall first, and then cut out the window openings. You can use the cutouts as inner shutters to cover over the windows that you want to make more secure, and hold them on with stud screws and wing nuts. Steel sheeting can be used much the same way if you are lining your building with it. Window bars and grilles are an option. |
Main doors should be placed so as to allow you the best access to where you need to go. Door frames should be rugged enough to hold a solid core door of either wood or commercial steel. Residential doors just don't cut it when it comes to security and protecting thousands of dollars of equipment, tools and projects that you have in your building. Outward swing doors offer more security and provide better emergency access if you should ever have to use it for that purpose. | Main doors should be placed so as to allow you the best access to where you need to go. Door frames should be rugged enough to hold a solid core door of either wood or commercial steel. Residential doors just don't cut it when it comes to security and protecting thousands of dollars of equipment, tools and projects that you have in your building. Outward swing doors offer more security and provide better emergency access if you should ever have to use it for that purpose. | ||
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Door location is paramount in the setting up of your garage or shop. It doesn't matter if it is the decision between using a single door or two doors on a small garage, or if you should put the door in the middle of the end walls of a large shop. Take out the graph paper and draw your garage or shop area out to scale. Use scale sized piece of paper or wood blocks of 10 X 20 foot dimension to "drive" into your garage and park your vehicles to simulate what is practical for your building size. Sometimes, offsetting an end wall door and parking diagonally will give you better access and utilization of your space. Try going double deep with the garage on a deep lot property, install a OHD on either end, use the back end to move cars under construction into rear yard for sandblasting and painting, while the front end is used for everyday use of the family vehicles. This keeps the neighborhood from getting down on your case. | Door location is paramount in the setting up of your garage or shop. It doesn't matter if it is the decision between using a single door or two doors on a small garage, or if you should put the door in the middle of the end walls of a large shop. Take out the graph paper and draw your garage or shop area out to scale. Use scale sized piece of paper or wood blocks of 10 X 20 foot dimension to "drive" into your garage and park your vehicles to simulate what is practical for your building size. Sometimes, offsetting an end wall door and parking diagonally will give you better access and utilization of your space. Try going double deep with the garage on a deep lot property, install a OHD on either end, use the back end to move cars under construction into rear yard for sandblasting and painting, while the front end is used for everyday use of the family vehicles. This keeps the neighborhood from getting down on your case. | ||
| − | ==Electrical | + | ==Electrical== |
| − | + | Rule #1: The supply MUST meet the demand with a safety factor of at least 40%. Start with a 100 amp service. 'Demand' fits in two categories; DEDICATED circuits and CONVENIENCE circuits. Lighting, compressors, welders, post hoists, ventilation fans & heating units, reel-trouble lights, refrigerators, etc., are DEDICATED. Bench and wall receptacles are CONVENIENCE, because you're never going to use them all at once. Sit down with a clean sheet of paper and document the electrical tools that normally don't move and consider each circuit and amperage. Some circuits may be used for two purposes, for example, I doubt if anyone would raise a hoist while using the MIG welder. So, that can be the same circuit. Figure for liberal lighting and NEVER put lights on the same circuits as your receptacles. If you trip a breaker (or GFCI) you won't be groping around in the dark. Add the number of circuits and note the circuit's ampacity. Total your amps and multiply by TWO (because we know you're going to get more)and that's what service you'll need. Service panels come by AMPACITY and NUMBER of SPACES. 230-volt breakers occupy two spaces. A typical Service Panel will have a 100amp main breaker and 24 spaces. You can go up from here if more spaces or more ampacity is required. | |
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| + | For CONVENIENCE receptacles, use #12AWG copper wire on 20-amp circuit breakers. 30-amp receptacles are normally dedicated to a stationary tool and rarely used as 'convenience' outlets. Don't forget that indoor and outdoor receptacles in a garage must be protected by GFCI's (either ground fault circuit interrupter breakers or GFCI outlets). If you protect the first of the outlet boxes in a circuit with a GFCI outlet, all the rest of the outlets may be protected too. A compressor or 220V mig will eat up 30 - 40 amps. Two-post hoists and 230volt MIG welders normally require 20-amps. "Brown outs", lack of correct power will fry a motor over time. If that shop of yours is getting a regular workout, maybe you should go with a new 'drop' instead of drawing off the house circuit. Better yet, stay away from using aluminum wire. Use copper because it rarely needs future attention, wire sizes are smaller for the same amperage, and it has a far better voltage drop over long runs. Electrical supply stores have copper wire in all sizes if your local 'box' store doesn't have it. | ||
| + | Motion detectors work great and are a deterrent to crooks. Point one at or above your entrance door (I also have one inside my garage for when the wife pulls the car in). This is particularly useful in winter months when days are short and weather is cold. BTW, if you live up north, stay away from fluorescent or any lights that use ballasts because if they start, they take a while to put out decent light. Use lighting fixtures that take regular light bulbs with standard 'medium' bases. Fluorescent lighting is fine in heated areas. | ||
| + | Consider running all your wires in metal conduit, surface mounted on the interior walls. If you get your shop all wired up and the wires are buried in the walls, it will be inconvenient to change anything later. If you don't like the look of exposed pipe, notch your studs and use thinwall (EMT) conduit. I keep my shop fireproof by using plasterboard (gypsum). It's cheap, clean, warm, durable and easy to repair. Oh, and a torch will not go through it. Bending thinwall is simple with practice. Have an electrician show you how the bender works because there's a lot more than meets the eye. | ||
| − | + | Electricity is very dangerous, and should be handled by qualified Journeyman Electricians. They adhere to the National Electrical Code book, written by the National Fire Protection Agency. You want this level of training and you want their work inspected for insurance purposes. Most cities offer 'Homeowner's Electrical Permits' at a reduced cost. It's perfectly ok to do this work yourself; just hire qualified help. Most inspectors are eager to work with homeowners if they get permits BEFORE work starts. They gladly answer your questions and give sound direction. When an inspector finds "bootleg" work, that's when they get upset, and naturally so. | |
| − | It's nice to have a shower in the shop, especially after sanding fiberglass filler (this also prevents complaints from your spouse about the oil slick you leave in the bathroom after showering. If your budget warrants it and you have the room, a 800 to 1200 gallon holding tank is a great investment to hold the sewage and grunge that comes out of a garage. You can also put in a floor drain connected to a dry well to take gray water from washing your vehicles. Check your local building codes to see if they are allowed in your area, and don't be tempted to use the floor drain to get rid of anything else. | + | ==Plumbing== |
| + | Plumbing is a welcome addition to any shop. No more running to the house for a pail of water to fill the radiator or wash off body filler dust. You want water close by if you weld or grind. Getting water to the shop is easy -- getting sewage and gunk away is the problem. Limiting factors effecting effluent disposal are climatic conditions, topography, municipal concerns, and about twenty other things. | ||
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| + | It's nice to have a shower in the shop, especially after [[sanding]] [[Fiberglassing|fiberglass]] filler (this also prevents complaints from your spouse about the oil slick you leave in the bathroom after showering). If your budget warrants it and you have the room, a 800 to 1200 gallon holding tank is a great investment to hold the sewage and grunge that comes out of a garage. You can also put in a floor drain connected to a dry well to take gray water from washing your vehicles. Check your local building codes to see if they are allowed in your area, and don't be tempted to use the floor drain to get rid of anything else. | ||
==Heat, ventilation, and air conditioning== | ==Heat, ventilation, and air conditioning== | ||
| − | Garages have always been | + | See: [[Garage heating]]. |
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| + | Garages have always been social places, but it seems that we are seeking more and more creature comforts coming into the garage each day. If it's cold out, heat it. If it's hot, cool it. It's that simple! No one wants to be working with sweat dripping from their crotch, so why would you want to do that in your garage. If you're welding, spraying paint or have grinding dust, you need ventilation. A wall type ventilator fan with exterior shutters is excellent, even a squirrel cage furnace fan stuck up in the gable end wall in the attic area will take away a majority of the noxious fumes and dust particles. A fresh air source is mandatory if you're using any kind of fossil fuel for heating. A CO2 monitor is also a good idea in a garage. | ||
Yes, you should have air conditioning. If you're comfortable, you'll stay in the garage longer and out of your spouse's hair. It keeps the bugs out of your beer, and you deserve it. | Yes, you should have air conditioning. If you're comfortable, you'll stay in the garage longer and out of your spouse's hair. It keeps the bugs out of your beer, and you deserve it. | ||
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==Accessories== | ==Accessories== | ||
| − | After you have four walls, a roof and a floor, pretty much everything else is just window dressing.These are all the 'I WANTS'! Got $30,000 worth of tools and parts in your garage or shop? Put in a lockable tool crib to house them, or be prepared to lose them over time. | + | After you have four walls, a roof and a floor, pretty much everything else is just window dressing. These are all the 'I WANTS'! Got $30,000 worth of tools and parts in your garage or shop? Put in a lockable tool crib to house them, or be prepared to lose them over time. |
Plan out shop layout and place equipment in proper areas. Use graph paper and cut outs of proper proportions of equipment to see if it fits and works in the plan. Locate compressors and lines the same way. | Plan out shop layout and place equipment in proper areas. Use graph paper and cut outs of proper proportions of equipment to see if it fits and works in the plan. Locate compressors and lines the same way. | ||
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===Shelving=== | ===Shelving=== | ||
| − | Install dependable steel shelves and cabinetry with proper labeling to identify the tools | + | Install dependable steel shelves and cabinetry with proper labeling to identify the places for your various tools. Make sure that shelves are capable of handling the weight that you will place on them. One option is to use wire adjustable shelving -- it comes in varying widths and lengths, the dirt and dust falls right through, and you never have to climb up to see what's on the top shelf. Add colored bins and boxes, and it starts to look like a well organized shop. One option for independent shelving units are the "Gorilla" shelf units, available at Costco. The "Gorilla" shelves have a powder-coated angle iron frame with high density wood shelves, and are diagonally braced to prevent shifting. If you're worried about shelf units tipping, just add a turnbuckle, or a hook and eye from the wall to the unit for extra stability. |
===Cabinets=== | ===Cabinets=== | ||
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===Storage=== | ===Storage=== | ||
| + | ====Indexed stackable plastic containers==== | ||
Here's one way to handle garage storage. | Here's one way to handle garage storage. | ||
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Then, when you're looking for something, you can first check the book, then look for the tag with the matching number. When you add or remove something from a container, you can update the entry in the book. | Then, when you're looking for something, you can first check the book, then look for the tag with the matching number. When you add or remove something from a container, you can update the entry in the book. | ||
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| + | =====Hanging plastic containers from ceiling===== | ||
| + | For details on building a ceiling rack from which to suspend plastic totes, see [http://www.alpharubicon.com/kids/garagestoragetluweyen.htm this article]. | ||
====Tire rack and cord rack==== | ====Tire rack and cord rack==== | ||
| − | Every shop should have a tire rack and cord rack. | + | Every shop should have a tire rack and cord rack. Tire racks can be place on the front part of the shop over top of bench or storage areas. Use 1 1/2" square tubing as a frame work and make sure the uprights come down to the floor for support. Don't just rely upon the perimeter horizontal rails to wedge the tires up, place a center rail to avoid tires falling through. An eight foot tire rack will hold a dozen tires and rims. |
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| + | Cord racks can be made from 1 1/2" tubing with properly spaced large S-hooks or junkyard tire irons welded to the horizontal tubing. A couple of used rims mounted on the wall will do in a pinch. Air and water hoses can also be hung on the wheel rims, the large radius will avoid stress cracks forming in them. | ||
==Specialty areas== | ==Specialty areas== | ||
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If you are working with old iron, try building a separate area for racking your steel, or, a separate sanding blasting room with proper ventilation and good lighting. If you work on auto fabrication, why not have a frame jig table or a rolling overhead crane to move frames and engines into place. If auto body work is your game, how can you design it to keep the dust from overtaking all of the building? Maybe a simple divider and an exhaust fan will keep the dust and dirt under control. There are many considerations, plan them out and be open to new valid suggestions. | If you are working with old iron, try building a separate area for racking your steel, or, a separate sanding blasting room with proper ventilation and good lighting. If you work on auto fabrication, why not have a frame jig table or a rolling overhead crane to move frames and engines into place. If auto body work is your game, how can you design it to keep the dust from overtaking all of the building? Maybe a simple divider and an exhaust fan will keep the dust and dirt under control. There are many considerations, plan them out and be open to new valid suggestions. | ||
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| + | ==Resources== | ||
| + | *[http://www.hotrodders.com/kb/garage-buildings Garage Buildings] | ||
| + | *[http://www.home-garage-help.com/index.html Home-Garage-Help.com] | ||
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| + | [[Category:Good articles]] | ||
| + | [[Category:Garage and shop]] | ||
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