Galvanized

the branch studio fountain 2016Every winter, the Branch Studio fabricates a new fountain or two. Some years that fountain is classical in form. Classical garden fountain style interpreted in steel interests me, and our clients. Our fountains come ready to fill, plug in, and turn on. There is something about water in the garden that enchants, so I like to make it easy as possible to have. Some years our winter fabricated fountain is contemporary. We have in the past fabricated an elliptical and rectangular steel fountain with a congested steel rod surface. The rectangular fountain has over a mile of steel rods welded to its exterior, and weighs close to 4000 pounds. Have you seen it?  The elliptical fountain has been placed in a private garden. In the interest of fabricating a one of a kind fountain, our newest contemporary fountain is a shape we have never done before.
The Branch Studio fountain 2016 (3)This winter, our contemporary fountain from Branch is spherical, and features our signature stick like and prickly surface. A pair of steel hemispheres, 64 inches in diameter,  got welded together. We sliced the top third off that welded hollow sphere.  The remaining 2/3rds of a sphere became the armature for this fountain. Owen and Riley, with followup from Sal, spent a good bit of the winter welding sticks of all different sizes to the surface. Our group of companies, Deborah Silver and Company, who designs and installs landscapes, Detroit Garden Works, who retails just about everything beautiful and useful for a garden and landscape, and The Branch Studio, who fabricates whatever garden ornament a gardener or landscape designer might dream up for a project –  hope to help every gardener and landscape designer get where they want to be with their landscape. But in the dead of the winter, we just express ourselves, and keep our fingers crossed there will be a client who hears what we have to say.

The Branch Studio fountain 2016 (1)Branch created this fountain for the garden strictly on speculation. Why would I speculate?  All of the Branch fabricators, and the studio head, Buck, are very creative people. They need a project once in a while that allows them to stretch their wings, and fabricate something new. This is a breath of fresh air for our group. It creates excitement in the studio. And is is good for a client seeking a very unusual and one of a kind ornament for the garden.

The Branch Studio fountain 2016 (2)The Branch group handled the fabrication of this fountain like they were born to make it. Once the stick making had covered the surface, a decision was made to leave the 6″ wide return plain. The contrast of one complex surface to the other plain one is striking and pleasing. The fountain jet will be fabricated next. The jet pipe will mimic the spherical shape and construction of the fountain. Water from the jet pipe splashing over a rod steel covered sphere will be quite musical.  The sound of a fountain is a considerable part of its attraction.

20160419_124028 (2)Clients considering the purchase of Branch containers are concerned about the longevity, and the durability of their resistance to rust, and rightfully so. Everything we manufacture is meticulously hand fabricated with heavy gauge hot rolled steel, with a lifetime of service in mind. The cost of them reflects this. What we do to prevent rust is considerable. All of our containers, fountains, and garden ornament are sent out for galvanizing after it is fabricated. Our galvanizing company has a zinc tank  6 feet wide, 8 feet deep, and forty feet long. This shape has everything to do with the fact that most steel that comes here for galvanizing are steel beams using in the construction of building, bridges, and so on. The plant manager was dubious the day we arrived with our first load of garden containers. 13 years later they know we are as serious about rust prevention as we are about beauty. We pay for galvanizing by the pound.  Our scale at Branch only weighs objects up to 2000 pounds.  This fountain went over the 2000 pound mark.  We won’t know what it weighs until after the galvanizing is complete. The fountain is lifted with a bridge crane via steel straps in preparation for the dip.

20160419_124120This tank holds 824,000 pounds of molten zinc, heated to about 900 degrees. The galvanization process completely immerses the raw steel object in molten zinc, very slowly.  The shock of the heat to the steel is considerable.  Steel which is not thick enough can be damaged by the plating process. The molten zinc coats every surface with a skin of zinc. How much of a skin?  This fountain will weigh 20% more once it is galvanized. This means that a 3000 pound object will emerge with 500 pounds of zinc coating its surface.The fountain was lowered into the tank ever so slowly.

20160419_124757 The shop foreman made a trip up to Branch to inspect what we had a mind to galvanize, before we took the fountain to them. An object of this size and complexity is a once a year project for us. There are logistical issues that need to be addressed in advance. There was plenty of discussion about what it would take to get the fountain to sink slowly and evenly. An object that floats on top of the molten zinc is a problem object. Our big spherical fountain had lots of holes drilled in it, which will be repaired with galvanized steel discs once the galvanizing process is complete. Our garden boxes have loose galvanized plate steel bottoms which are added after the boxes are galvanized. A box with no bottom sinks in the zinc bath.

20160419_124729The fountain took as long to emerge as it did to descend.

20160419_124500A molten zinc tank always has floating hardened zinc and impurities floating on the surface.  Prior to and during the galvanizing of this fountain, the surface of the molten zinc got raked, so those impurities would not be deposited on the surface. Occasionally a glob of something will stick to an object.  If it is chipped off, or ground down too hard, the integrity of the galvanizing might be breached.

20160419_124541If a galvanized object from us develops a small rust spot, it will do so within 2 weeks of being outdoors. That spot can be repaired with cold galvanizing compound. A breach in the galvanizing is a rare occurrence.

20160419_124549The moment any steel object emerges from a zinc bath sports a shiny as silver color. Once that object comes in contact with the air, that shiny surface begins to oxidize, and will become that dull gray color one usually associates with galvanized metal.

20160419_124649The process by which Branch fabricates, finishes, and sells their garden pots, fountains, pergolas and ornament is all about beautiful design and fabrication, and a thoughtful and serious finish that is unlikely to need any maintenance. My thanks to the plant manager for taking these pictures for me.

spherical Branch fountain (2)Back at Branch, the fountain is awaiting our final signature finish, which will give the steel that blue gray patina which is reminiscent of lead. Heather, who handles all of the Branch Studio inquiries, came with me for a look see today.

spherical Branch fountain (1)I am sure this fountain will be up and running soon.

A New Gravel Driveway

landscape under construction (8)I admire people who buy old homes, and sign up for all that it will take to renovate them. That is a huge commitment in every regard. An undertaking such as this demands lots of time and even more patience. I cannot imagine the expense. This gorgeous English Tudor style home is 95 years old. Very old homes like this one are remarkably sturdy and well built. I own a house built in 1930, and I can attest to how rock solid it is. I can barely drill a hole in my steel mesh reinforced plaster to hang a picture. That plaster and brick set over concrete block walls means that my house is incredibly quiet and structurally sound. This home features a virtually indestructible brick fired from a clay body featuring a big mineral content – manufactured with the idea of longevity and service in mind.  A good bit of the trim is hand carved limestone, all of which is excellent condition. The new roof is slate; slate roofs last just about forever. But great age exacts a toll on the working parts of an old house. Every house is a small city. It needs electricity, heat, air conditioning, weather tight windows, plumbing – this is a short and not comprehensive list. What got updated here is just about everything, and took a year and a half to accomplish. A kitchen and bathrooms that worked well in 1920 were reworked from the ground up. The interior renovation of this house is finished, and is finished beautifully.

a new driveway (1)My client’s interior designers introduced me to them and their property.  Eventually they would turn their efforts towards the landscape. Last year’s landscape efforts were concentrated on a pool, terracing, a spa, and an astonishing pergola built and installed by the Branch Studio. Screening trees, and a large collection of small spring flowering bulbs got planted late in the fall. This year, we hope to plant the front, side, and rear yard landscape. The property had been neglected for decades. The gravel driveway, all but invisible under a thatch of compost and weeds, was lined in concrete curbing that went 24 inches below grade.  A number of trees grew up, and spent decades thriving. Many of those trees were now were in serious decline.  Disease and fierce weather had taken their toll. The roots had grown over the curb, reducing the width of the drive to just over 8 feet.  A new driveway design and installation would need be the first part of the installation of the landscape.

a new driveway (13)Once the front yard landscape was agreed upon, there was a lot of work to do. Once the dying and diseased trees came down, the stumps were loaded into a 30 yard dumpster – almost 12 tons worth. That is a staggering number, and it explains why so many large machines are parked in the front yard. Taking apart an old landscape and driveway is a shocking experience, but bare dirt that is asking to be regraded is a big breath of fresh air. It is never an easy thing to abandon what was, and go on.

a new driveway (12)Once the drive curbs and the trees were removed, the ground had to be graded.  In this case, there was quite a bit of what I call balancing to do.  The land which was high on one side was lowered, and the low side needed to come up.  From the street, the land would look balanced, left to right.

a new driveway (4)The grade of the driveway would determine the final grade of all of the land surrounding it. A large motor court some 56′ feet wide by 32′ deep would be a dominant feature of the landscape. This would permit off street parking for clients who entertain regularly. But most importantly, a gravel drive and motor court seems appropriate for a house of this age and architecture. It interests me that many very old homes with motor courts were built before the advent of motor traffic. It can be a beautiful feature in and of itself. The accompanying landscape would in a simple way feature the house and gravel court.

a new driveway (2)In many respects a gravel drive is simpler and somewhat less expensive to install than concrete, asphalt, or stone.  One of the biggest expenses is the cost of the edging. The gravel must be contained.  A hard boundary is what keeps the gravel in place.  Gravel that has crept away from its intended location can look great in a very informal setting. It would look messy and untended in a house of this architectural formality.

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Both the drive and motor court are edged in 1/4″ thick steel.  That steel edges is secured by steel stakes that are driven into the ground through steel loops welded to the back of the edging. The steel has to be this thick to withstand repeated vehicular traffic, and stay in place.

a new driveway (6)The gravel motor court will be bordered in concrete paver brick, three bricks deep.  The border will help to visually reduce the size of the gravel area. It will also recall the brick on the house. This brick will be dry laid between parallel bands of steel edging.  Concrete brick can better withstand compression weight of a vehicle. Pictured above is a base layer of compacted road gravel.  The finished crushed stone will be added at the very last, at the height you see indicated by the top of the steel edging.
a new driveway (5)A large new blue stone front walk will make beautifully clear the location of the front door. The house is not symmetrical in its footprint.  The walk which is large enough to feel like a terrace is a centering gesture. There is plenty of room for containers out away from the front door. This exterior entry way echoes the scale of the spacious foyer just inside.

a new driveway (9)An important element of designing any driveway is to check if it is driveable.  My clients drove it a number of times when the scheme was painted on the ground. One little but significant change was made to help anyone backing down the drive stay in the lane. A driveway that doesn’t work well always shows where that pinch point is. Curves and changes of direction need to be gradual and sweeping.

gravel drivewayThe drive at the back will be installed as concrete aggregate, rather than compacted gravel. This will make it easy to shovel a path from the detached garage to the back door. The forms are being set for this portion of the drive. An iron fence and gate appropriate to the architecture is to come soon.

a new gravel driveway (3)The bed lines near the gate to the back yard were specifically set to allow my clients to back out of the garage, and turn around.

a new gravel driveway (2)As of late yesterday, the finish gravel has been put down in the motor court. The concrete brick is due to come in today.

a new gravel driveway (1)At the last of the day, a pair of 25 foot multitrunked katsura trees were added to frame the view of the house from the road. The landscape will be underway shortly.

 

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.

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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.

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

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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.

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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)

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hanging the lattice panels (3)hanging the lattice panels

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the finish (3)

Branch Studio pergolaThe finish

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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

 

Landscape Under Construction

landscape under construction (8)A long time has passed since I first laid eyes on this lovely old home in Detroit. Dating back to the 1920’s, all of those beautiful details built in to homes of this era were intact.  The front door has a gorgeous hand carved limestone surround. The brickwork and slate roof are sensational. Gorgeous bones, everywhere. My clients were willing to put what it would take to restore and re imagine the interior to their taste. Every move they made paid great respect to everything original. As for the landscape, there was work to be done. They consulted me about the landscape early on. They both have a love, an appreciation, and a respect for all things green. They were interested in a landscape that would permit them to grow vegetables, a small conservatory in which to grow plants all winter, and a place to be outdoors as much as possible in the summer. Both are very busy professional people for whom a beautiful landscape and garden would be a sanctuary, a delight, and a place to grow plants, and to host friends and family.

landscape under construction (5)The interior renovation took a long time.  This gave me plenty of time to consult with them about where they wanted to take the landscape.  It is obvious from these pictures that no one had cared for the property in a very long time.  The weeds were old, tall, and woody. Some tree seedlings were over six feet tall. There were dead trees, and trees in poor condition.  What shrubs had survived were unkempt. None of them were precious or unusual, but for a group of multi trunk yews in the front yard that were old enough to have attained tree status. They are breathtakingly beautiful, and thriving. The back yard needed some thoughtful design.

landscape under construction (6)Their interior designers, Arturo Sanchez and Barry Harrison from Art Harrison Design Studio made some great decisions early on.  The kitchen windows in the center of this photograph would become French doors.  This would make a trip from the kitchen to the barbecue convenient. There was a great interest in a terrace that would be friendly to dining and entertaining. The question about how to handle the rear terrace would be mine to explore. The other kitchen windows beyond the wall in this picture would be looking out onto the driveway. Driveway?  The drive outside this wall was gravel, and covered in a thick layer of compost and weeds. Once all of the construction was finished, the driveway would be redone. How would that view be handled?

landscape under construction (7)
The wall which connected the house to the garage had been beautiful in its day.  It would need to be rebuilt.  And perhaps rebuilt in some other configuration. Designing the walls and hard surfaces would come first.  But there needed to be a concept established for how the entire space would work.  They wanted to cook and entertain outdoors.  They wanted a pool.  They wanted a spa they could use year round.  A conservatory was on the list. Perhaps the conservatory could be located behind this wall. This is an urban property with 3 neighbors.  How would we establish some privacy in the rear yard?  How could we maximize the the outdoor living spaces?

landscape planThis conceptual plan for the entire property evolved over a period of time.  The design for the rear yard is at the top of this picture.  The rear terrace would span the space from the new kitchen doors to the entry to screened porch at the opposite side.  Given a terrace of this size, there would be two sets of steps down into the back yard. The spa would be situated just below that terrace.  The pool would be round.  The rear yard is not that large.  A round pool would fit the space with ease, and be conducive to entertaining. As the grade of the rear yard rose the further one was away from the house, the pool was designed to have its front half out of the ground, with a coping set a seat height.  The rear half of the pool would be set at grade.  Beyond this round pool would be a pergola-the design to be determined. Once my clients were convinced that the round pool, and the terrace with a curved front and dual stairs was to their liking, the discussion turned to all of the details.

 

Branch pergola (3)A good bit of time was devoted to the design of the pergola. Eventually it was decided that the pergola would have curved wings that would follow the radius of the pool. The center section would be round, and have an open roof. The posts at the back would rest on a brick wall at seat height. The back of the pergola would be finished with lattice panels, for privacy.  The poles in front would sit at grade.  In the center, a round pavilion with a curved roof. This center section would provide ample space for a large dining table and chairs. The Branch Studio would manufacture the pergola.

Branch pergola (2)This picture of the finial to go on top of the finished pergola gives an idea of the size of the finished structure.  There will be lots of space to entertain.  A swimming pool can be a beautiful and welcome feature in a landscape.  That feature asks for a place to be, pool side.

Branch pergola (1)Each piece of the pergola will be fitted together prior to the galvanizing process, to be sure everything fits. The body of the pergola can be installed by the landscape crews, and the Branch crew put together, but the roof will have to be set by a crane. If all goes well, that pergola should be ready for installation in less than a month. landscape under construction (4)The terrace, pool, and spa were well underway by time winter arrived last year.  The pool terrace, and the new wall separating the back yard from the driveway would have to wait until this spring.

landscape under construction (14)It has taken more than 5 months to complete all of the stone and brickwork, and the pool.  The area in the foreground which will be occupied by the pergola has been barked, to keep the dirt and dust down.  This area will be graveled with decomposed granite, to provide a hard yet water permeable surface.  The back of the pool sitting at grade is accompanied by a generously sized terrace perfect for lounges and containers.  The back wall of the pergola features posts which will be set into a brick seat height wall with blue stone coping in the immediate foreground.

landscape under construction (13)The spa sits just below the house terrace, making it convenient for winter use.  The ground between the spa and the pool will be lawn.  On the left side, a wild flower and shade garden loaded with spring flowering bulbs will feature hemlocks and dogwoods.

landscape under construction (10)On the rear lot line, a hedge of recently planted American arborvitae provides loads of instant privacy to the yard. The shade garden will curve around and blend into this hedge.

landscape under construction (12)A dressing room is in the process of being built off the back of the garage.  And the conservatory?  it will be built on top of the brick wall off the side of the garage.

landscape under construction (11)The new brick wall dividing the garage and driveway from the back yard is soon to get an iron gate. On the backside of these walls, we will plant gardens.  The driveway garden is always an important garden. Everyone visits that garden at least several times a day, all year round. Now that the hard surfaces are done, I can revisit the landscape plan, and see if anything needs to be changed.  It is always a good idea to let the space speak back to you before you plant.

Sept 2, 2015 (10)Once the pergola is installed, I will better be able to judge where any additional trees and shrubs should be planted. The shade garden down the side of the yard needs to be integrated into the hard surfaces and spaces.  Will I plant on the pergola?  If course.