Week 4: Excavation

This week is probably the peak of craziness in our construction project. On Monday, the excavation and concrete team arrived with three bucket excavators, a loader, a mobile air compressor and a couple jackhammers. The began by knocking out the remaining brick opening in the rear of the building for access. Matty Kemp has been helping with demolition and here he smiles in appreciation of big yellow machines doing their thing.

After that hole was made (note the new steel beam that was installed last week) they started cutting two holes in the floor joists. Hole #1 is just inside the building and allows the excavator to scoop into the basement and then rotate and drop in the dumpster. Once they are done, this hole will be occupied by a trash enclosure and a new staircase.

Hole #2 is for the fermentation cellar, which will be a 2-story space (basement & 1st floor). This part of the brewery will be a fishbowl like Goose Clybourn down the line and the extra tall ceiling will accommodate extra tall tanks someday soon. Here you can see the subfloor and joists being removed. Parts of the two massive beams were cut away later. Even old growth Douglas Fir wood melts like butter at the hands of a chainsaw. I'm spinning my minds about how to reuse all this wood and the leading candidate seems to be benches in the fireplace lounge.

The rest of the week, the guys have been jackhammering the concrete pad in the basement and wheelbarreling the chunks to the back corner to Hole #1. They are just starting to excavate the hole for the serving tank walk-in cooler under the bar. Hopefully next week we'll start the underground plumbing.

Upstairs Matty, Stephen Jablonski and I continue to gut the office space. I'll admit to being pretty tired from all the manual labor at this point, so I'm enjoying a few days of rest. For those of you watching the clock, we are making great overall progress so far in construction. Unlike the financing stage which was rife with process delays, we are steaming ahead full speed.

People often ask, 'What kind of beer are you going to make?" I usually give a snappy "lots" or "all kinds" response since nothing is set in stone yet. But just to give some guidance, Handlebar has Bell's Hopslam on tap right now, and I think that if I could only brew one kind of beer that would be it. It's made with honey, but doesn't have the usual overbearing sweetness you often get.

Demo Party

We got lots of work done at this past weekend's Demo Party. With about 15 hands on deck, we knocked off some mundane but important tasks:
  • Filled a dumpster with drywall and other debris from the second floor offices.
  • Emptied out the basement to prepare for the jackhammering of the concrete pad this week.
  • Demolished a few remaining walls upstairs.
  • Took down the florescent lights and suspended ceiling in the office space
  • Dropped all the lumber from the old partition walls down from the second floor for future removal.

I also managed to find the weak spot in the floor with the rear wheel of the forklift. After trying to push the stuck three-wheeler out of the hole, Steve correctly figured that we needed to rampantly violate the safety sticker and counter balance the lift if we were going to get it out.

In the end, after a hard day's work, it was Revolution Time and the dust masks came off for the day. Thanks go out to Michael, Steve, Mike, TC, Steve, Josh, Paul, Dan, Elliot, Ravi, Cheryl, Ben and anyone else I missed.

Week 2: It's a Wreck!

The second week of demo is wrapped up. On the first floor we've removed the lath and plaster and revealed the brick walls. We also pulled down the tin ceiling in the back section of the space that won't be visible to the public. It's natsy, black lung kinda work.

Not much is happening in the basement, but that should change this week as the masons and excavators arrive and get to work. Upstairs, I've been wrecking the old office space. As I had hoped, the hardwood floors underneath all the carpet are in great shape most everywhere. Not that you can see them under the cloud of gypsum dust, but they will shine up well someday.

Although I enjoy the zen of swinging a sledgehammer alone, I'm organizing a Demo Party next Saturday the 31st. If you're the kind of person who enjoys loading old acoustical ceiling panels and rolls of carpet into a dumpster, send me an email at josh at revbrew.com to join in the fun (We've got enough help signed up!). We'll work for a few hours emptying out the second floor space. In a nod to the big picture, pizza and beer will be provided.

Week 1: Electrical Demo

We started our first week of construction slowly with the beginning of demolition work. The old electrical system is being dismantled as we prepare for the new 1200 amp service to arrive. During construction we'll have heat, work lights and a working elevator, a few outlets. At least that was the idea.

While doing some demo of the 2nd floor this weekend, I ended up trapped in the freight elevator. I was about halfway between the first and second floors when the car lurched and then stopped. The light stayed on (fed through a separate circuit I learned later), but the motor which spins the wheel which lifts the car was unresponsive. It's an open car so I ended up climbing up and out the second floor door a few minutes later. After popping open the first floor door I could see that the flexible power cord attached to the bottom of the car got caught of part of the elevator rail mechanics and either loosened its wires or shorted out a fuse. When the icy roof thaws, I'll check out the fuses in the machine room and try and get things working. I should be happy to be alive right? Like other issues that have come up, throwing some more money at this problem should make it go away.

After that mishap, I continued on with the demo of the 2nd floor which I'll be doing myself. The former building owners finally finished moving out this week and they left behind a mound of debris. I've just about got that mess under control and am starting to rip down all the cubicles and partitions. Once those are gone and the drop ceiling comes down the place will really open up.

Back downstairs, one reason the electrical is being removed right away is so that the mason can open a big hole in the rear wall for the excavation work. Eventually he'll build a new wall a few feet in the building to leave a trash enclosure off the alley.

Reader: Hops Dreams

Chicago Reader contributor Martha Bayne charts our progress with an article in this week's edition.

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