Posts Tagged ‘Time Lapse’


Previous Time Lapse Posts




Operation Dirty Green – November Construction Update

Tuesday, December 2nd, 2014

For the last few months we’ve been saying “the brewery is finally coming together” – but for the first time ever, it’s now actually coming together.

Bar
The bar is finally finished. Fireman Dave poured 9 gallons of epoxy over this thing and it’s now ready to commence vigorous testing – hence the kegerator behind it. You may also notice that while modeling the bar, Brie had to put her purse on top of the bar. Don’t worry, we have a solution for that coming.

brie-bar

Wall
As some of you may remember from the build-out blog from our current brewery, there is a requirement that we separate the brewery from the tasting room with a wall. This time we decided to get fancy with it – and at the same time doubled its zombie defense rating from 10 zombies per minute to 20.

15-bbl-zombie-wall

Brewery Programming / Testing
The brewhouse control system is debugged and ready to go. It’s waiting for a completed steam system before we can do a full hot water test.

Steam System
15-bbl-steam-system

And don’t worry. The most important part of ANY steam system has also been installed.
steam-whistle

Compressed Air System
We installed a big air compressor to power the brewhouse horns. One might ask why one would need horns when one also has a whistle, but that’s just a stupid question.

The air compressor will also be used to power our keg washer and air operated valves on our brewhouse and fermentors.

Tasting Room Lighting and Fans
We finally ripped out the gross florescent lights that come with pretty much all warehouses and put some nice barn-style lights and fans in.
lights-and-fans

Glycol System Complete
The glycol system has been one of the most labor intensive jobs. The chiller unit had been sitting in our tasting room for nearly 6 months while we figured out where to put it – it’s now on the roof.

After we mounted the plumbing, each elbow and tee needed to be covered with an insulation casing and then filled with expanding liquid foam. This might sound hard, but it turned out to be really easy – thanks to the fact that Chris married a girl that has a really handy father who did all the work (thanks Fireman Dave).

We’re within weeks of our first brew and pretty soon you’ll start to see some of the tanks pulled out of our existing brewery and put into commission at the new facility. As soon as we get our final building and safety sign-offs we’ll start planning our grand opening.

We’re almost there!

Concrete Installation – Part II

Thursday, July 10th, 2014

Part I of our concrete install, if you missed it, had demolition, wicked awesome construction machinery and loud noises. If you’re into that sort of thing (we are) – be sure to check it out.

If you’re more the type who loves sloped surfaces and latticed-rebar (we are ) – this blog post is for you.

Step 1: Vapor Barrier
The first step in pouring concrete is to place a plastic sheet over the dirt to prevent soil moisture from ruining the concrete.

Step 2: Rebar
With the vapor barrier in place, rebar dowels were drilled into the sides of the old concrete and epoxied in place. These ensure the new concrete slab adheres to the surrounding old slab. With the dowels in place, workers laid additional rebar across the opening in a lattice pattern (a pattern seldom used outside of pie and gardening circles) and tied it together.
rebar sloped floor drain new brewery

Step 3: Concrete Pouring
At 6am on a Thursday the cement mixer, pumping apparatus, and about 15 concrete workers showed up and immediately began working. These guys were organized & efficient – this was by far the most exciting part to see.

matt in front of cement mixer-annotated

Cement Mixer

cement pumping apparatus

pumping apparatus

All of the concrete work was performed by Dennis Mesick from Ideal Concrete Worx.

dennis infront of concrete - annotated

Step 4: FRP
Since we needed to wait 2 weeks for the concrete to completely dry, we decided to knock out some tiling and FRP wall paneling. This was our second time doing both tile and FRP so it was a little less of a circus.

Step 5: U-Crete
After spending lots of money on a fancy new slopes slab, the last thing we wanted to see was a bunch of cracks, mold and erosion start to set in as soon as we started brewing. Therefore, we got one of the best coatings money can buy: U-Crete. U-Crete is a cementitious urethane coating that’s designed to take lots of abuse. Unlike epoxies, it won’t crack when the concrete expands and contracts. Applying U-Crete consisted of the following procedures:

  1. Shot blast the concrete to open up the pores for better adhesion.
  2. shot blasting concrete

  3. Apply a base coat and cover it with sand.
  4. prepping for u-crete

  5. Vacuum up all the sand that didn’t stick to the coating after it dried.
  6. sucking up the leftover sand

  7. Apply a final coat
  8. applying final u-crete coating

The final sloped floor drain coated in U-Crete is sure to be the highlight of the next brewery tour. You won’t want to miss it.

And once again we leave you with a time lapse video of the construction being done. The Benny Hill Soundtrack really captures the essence of our build out.

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Concrete Installation – Part I

Wednesday, June 4th, 2014

After 3 rounds of plan-check approvals with the city, we were finally ready to start turning our dirty old warehouse into our beautiful new brewery. First up after plan approval was to paint and start on the 1,400 sq ft sloping floor drain where our brewery will be. This was done in five steps:

Step 1: Move All Equipment
We still have all of our storage over at the new brewery, so to prepare for painting we spent a night fork-lifting all our grain racks, barrels, etc. into the center of the facility so painters could paint the walls where the new brewery will be located.

Step 2: Move All Equipment…Again
Another step, another night playing Tetris with all of our equipment. To make way for painting the tasting room ceiling, the equipment that we just put in the center of the brewery was moved to the left side of the facility.

Step 3: Saw Cut
Finally a step that did not require our now-advanced fork lifting skills. Ventura Concrete Cutting came out to cut the perimeter of the drain area. Surprisingly the concrete saw was whisper quiet allowing us to get some more work done in the unit while they were cutting.

Step 4: Concrete Removal
The day after cutting the perimeter of our drainage area, Dennis and his crew from Ideal Concrete Worx arrived with a dump-truck and a Bobcat equipped with a jackhammer and started busting up the floor.

dump-truck-bobcat

Dump Truck & Bobcat

bobcat-jackhammer

For a full day,the Earth shook.

cut-up-brewery-concrete

Brewery floor all cut up.

Step 5: Install Plumbing
After the concrete rubble was removed, Mark Johnson came and began installing the piping for the main drain lines. You may remember Mark Johnson from previous brewery plumbing episodes.

installing-plumbing

Installing Plumbing

Recap
They say a picture is worth a thousand words, and so that means (assuming there are no diminishing returns) that 2,000 pictures is worth 2,000,000 words. So, we bring to you this 2,000,000 word description of the first phase of our build out in the form of time-lapse-photography!

Stay Tuned for the continuation of the plumbing install and the pouring of concrete.

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