Building The Lucerne Pergola

the Lucerne pergola (2)Phase 1:  Design, engineer, and build  Once Buck had my sketch for the pergola, there were a lot of drawings that would need to be done.  The CAD drawings would indicate the angles, the rolling radiuses, and the exact sizes of every piece of steel that would be necessary to fabricate the piece. Buck constructed the pergola full size – down to the last bolt hole – in the computer.

the Lucerne pergola (3)

the Lucerne pergola (4)

the Lucerne pergola (5)

the Lucerne pergola (6)

the Lucerne pergola (10)Buck’s crew put the base of the pergola together up side down, to be sure every piece fit together properly. Owen was the lead fabricator on the project, with help from Adam, Riley, Sal, LaBelle, and Buck.

the Lucerne pergola (8)Lattice panels were designed and fabricated as an open wall for the back of the pergola, and feature a steel ball detail.

the Lucerne pergola (9) Each of nine panels were hand fabricated and fitted to each opening.

setting the structure (7)The installation: setting the structure.  The bottom of the pergola was bolted in the rear to a seat wall of brick, through the bull nosed blue stone coping.

setting the structure (5)

setting the structure (8)

setting the structure (6)The top of the brick wall is seat height, and width.

setting the structure (4)

setting the structure (3)

setting the structure 2The front post were anchored to 42″ deep concrete footings.

setting the roof beam (7)Setting the roof beams was the most difficult part of the job.  Each half-beam was 12 feet in diameter, and was incredibly heavy.  A support bar made especially to hold these beams, and a loader was necessary to get these pieces to the proper height for bolting on.

setting the roof beam (6)

setting the roof beam (4)

setting the roof beam (3)

setting the roof beam (2)

setting the roof beam (1)

setting the structure 2

the roof (2)Setting the roof.  These pictures are not so swell, with all that sky behind the action.  The top of the finial is 17 feet off the ground.

the roof (3)

the roof (1)

the roof (4)

hanging the lattice panels (3)hanging the lattice panels

hanging the lattice panels (1)

hanging the lattice panels (4)

the finish (3)

Branch Studio pergolaThe finish

Branch Studio pergola (2)

Branch Studio pergola (3)

Branch Studio pergola (1)

the finish (1)5 of the 6 Branch Studio dudes

the finish (2)The two day installation consumed 110 hours of work on the part of all 6 members of Branch. My clients had the great idea to do a time lapse video of the installation-what a treat this is to watch! If you are interested in watching, click on the link below.

the Lucerne Pergola installation


A Structure

steel-lattice.jpgEvery project, no matter whether it is big or small, begins with that first step. I had several months of communication via email from a design firm in Florida.  Could we build a pair of large scale pergolas for one of their clients?  The emails flew back and forth regarding the design and dimensions.  8 weeks ago we had a call.  The principal in this design firm would be flying up the following day to see Detroit Garden Works, and our operation at Branch.  We were happy to oblige.  Our design client was charming and discerning-that part was obvious.  As a result of that meeting, Buck had 2 very large garden structures to build.  A project of this size started with the first step.  The cut steel stacked on a pallet pictured above represents some 960 pieces of flat steel that would form the lattice pattern for both structures.

steel-pergola.jpgThe pergola roofs would be curved.  Gracefully curved. Curving substantial tubes of steel involves a process that is anything but graceful.  The proper tools and a measure of brute force more accurately characterizes the work.  Any big project that comes along asks for a person in charge who can imagine, and engineer-that would be Buck.  I sent this progress picture to our client early on.  These 8 pieces of steel would become a pair of roof structures.

steel-garden-ornament.jpgSo much engineering precedes the actual construction.  Buck figured out how to build these large garden structures such that they could be shipped.  As few pieces as possible means that the reassembly on site would be straightforward.  The frame of this short side panel is actually 3 pieces which would be unbolted for crating and shipping.

lattice-panel.jpgThe leg and beam panels were finished in a lattice pattern.  Three Branch fabricators welded the side panels lattice in tandem-from the ends to the middle.  The order of events, and the community action of an associated group of welders, is more critical than you might think.  The tremendous heat generated by welding can stymie the most careful design and planning.  Happily for this project, Buck had it all in hand.

finished-panels.jpgThe side panels for this pair of pergolas have been done for a few weeks. They are beautifully and precisely made.

pergola-roof.jpgThe construction of the roofs came last.  Those curved pieces of steel contructed weeks earlier were welded into place.

steel-garden-structure.jpgPrior to the finish of the roof, Buck put one structure together.  He needed to be sure that everything fit true, square and tight.  The orange apparatus you see on the ceiling in the picture above is a bridge crane.  The arm of the crane can move the block and tackle of the crane from one end of the studio to the other.  And up and down.  This makes it possible to handle the construction of very heavy objects.

finished-structure.jpgThe weight of this pergola?  Close to 2800 pounds.  I did take lots of pictures yesterday, as this may be my only chance to see this all put together.  I can imagine that once placed in a landscape, these structures will be stately and beautiful.  We are always appreciative when a client sends pictures of the things we make at Branch in the garden, but we don’t always get them. These will go to a private garden.

steel-pergola.jpgThe first day I walked into the building that would become the Branch Studio, I worried that I had bought place much larger than I would ever need.  Yesterday it occurred to me that the size of this building had not only inspired the imagination of our group, it enables us to take on large projects. The ability to produce work on this scale doesn’t come fast or easy. We had to grow up into it. There is an investment to be made in equipment and tools.  But more importantly, there are those talented and hard working people who are able to work together as a group towards a common end.  There’s lots of listening, and lots of teaching.

steel-roof.jpgOnce the pergola was all put together, I saw cellphones come out.  There were a lot of pictures taken.  A sense of accomplishment and pride was in the air.  As for Buck?  Once he saw what he had designed, engineered and built go together perfectly, he was one very happy man.

the second-roof.jpg
The last roof was finished yesterday. Are all these guys at home relaxing? No. They are at work today for a half day, building the steel cradle/ crates that will hold the pergola roofs during transport.  The crates are necessary, as the roofs are too wide to ship flat. It won’t be long now when a 48 foot long flatbed truck will back into the studio, be loaded, and haul these structures to Florida.  Well done, Branch Studio.