Last of the big pieces for the PNE

This past Thursday was delivery day for the last of the large pieces for the PNE. We loaded the two big pieces onto the low bed semi truck with a large crane in our yard and then headed into the city sixty-five miles distant. The trip went off without incident.

At the other end of our journey a second crane was waiting and we hooked up the pieces and hoisted them into place. The globe with the bugs holding it up weighed in at about 3,800 lbs. The dancing bug was then lifted up last and easily slid into position. Everything bolted into place in minutes.

It was a simple matter of hooking up the tree on the attachment points and slinging it into position. Our client will decide on a final position and then pour a concrete base for the sign. There are five bolt holes plasma cut into the steel plate base to facilitate permanent installation.

The ladybug holding the tuned out really nice. Ut's plenty sturdy with it's welded steel framework inside.

Since we dropped off the Flutterby sign/operator's booth last time they have installed the fence panels we did plus the ride. We are currently fabricating some gates and five more fence panels to complete this project.

Tree almost complete

The tree with the bug hanging the banner is also nearing completion.  I am delighted with how the routed banner is coming along. We added a subtle blend of darker red in the shadows of the banner to make the folds appear even deeper. It worked well. The piece is now complete save for a blend on the lettering.

Coat after coat of paint

The bugs were painted multiple coats of base colours and then a series of glazes to highlight the various bits and mechanical components. With each successive colour the bugs came to life. The painting is going well with two days left before we are shipping the bugs out we only have the final colours on the lettering left to do.

Bug Whirled tree in colour

The Bug Whirled tree/sign is also coming along nicely. The mechanical ladybug (Like all of the others) holding up the banner is a combination of mediums. The body of the bug is sculpted concrete while the arms, hands, legs and feet is Abracadabra Sculpting Epoxy.

Once the bug was sculpted we moved on to the final base coats of paint followed by the glazes. The tree is quickly coming to life.

Bug sculpting finished

It's been a busy last few weeks as we work hard on meeting promised delivery dates for the PNE Playland project. The mechanical bugs proved to be a lot of hand sculpting but the time we spent working on the fine details of the mechanics was well worth it. As soon as the sculpting crew was done the painting crew followed. We now have only a little painting left but already the bugs are looking spectacular! We can hardly wait to see them hoisted into position!

The dancing ladybug who will appear to twirl on the top of the globe as also coming along nicely. We finished the sculpting of the arms and legs today. As soon as the sculpting was complete the painting crew began the layering on of the paint and glazes.

Sculpting a wonderfully complicated tree

When I last left off the tree armature was still in the welding stage. Once that was complete the crew hand tied the galvanized diamond lath to the structure. They rediscovered what we have long known to be true. The more detailed the armature, the more difficult it is to tie on the wire, and the longer it takes. But all those twisted roots and branches are well worth the effort!

Once the wiring was complete it was time to begin applying the fibreglass-reinforced-concrete and then sculpt in the detail. The tree was large and complex which meant we had to do the job over three days. The first day we sculpted the bare wood (without bark) on the upper branches.

The second day we did the bare wood on the lower areas of the tree. This included some very detailed knots and roots.

On the third day we first applied a bonding agent where the bark would overlap the previous day's sculpted concrete. We then laid on the bark layer of the rest of the tree.

Today Jenessa used sculpting epoxy to form the rope over the structural steel rod which helps hold up the routed Precision Board sign. The sculpted some giant knots into the sculpt to make it believable. There is still a little sculpting to be done on the mechanical bug who is holding up the the other end of the banner but it won't be long until we are into paint. Stay tuned...

Delivery day at the PNE

You can't imagine the fun and excitement of one of our deliveries until you experience it first hand.

The latest began bright and early with a big crane pulling into our yard, followed by a semi truck and trailer. After a quick safety meeting to talk about the logistics of the move it is time to get to work. Each heavy feature is safely and securely hooked to the giant crane and then lifted into place. Careful attention is paid to safety as one of these pieces could easily hurt someone badly (or worse) if something failed.

Once everything is loaded the hold down straps are put in place and cinched tight. Everything is checked multiple times. For today's load we had to get an overweight permit and a special route was selected to ensure every overpass along the sixty mile journey was cleared with room to spare.

Peter and I rode in the chase vehicle keeping an eye on the load and straps as we travelled. It was a little like being in a parade as people took notice of the brightly coloured load as we rolled by. There were plenty of second looks, stares, waves and smiles along the route.

We kept in touch with our client as we travelled so they could coordinate their crews and heavy machinery for our arrival. When we arrived we again held another meeting to plan the unloading process and safety procedures. Then it was time to hook up the first piece and swing it into position. Everything had been carefully marked out in advance. The stump with the drum on top was the first.

Then the truck and crane were relocated across the property for the second phase of the unloading process.

The Flutterbye tree also was carefully positioned on it's predetermined marks.

The last crowning touch was the colourful Flutterbye which seemed to fly into it's place by magic. In the space of a few hours the first of two deliveries for this project was complete.

Bright coloured fun!

With the first delivery day imminent we worked hard to meet the deadline. The powder coater delivered all of the colourful parts with only hours to spare. We bolted the bright plasma cut flutterbyes onto the fence panels.

Inside the shop the tree sculpture is done.  little more welding was done to the temporary carrier frame to ready it to be fastened to the truck. It will soon be rolled out onto the parking lot in readiness.

The sculpting and painting of the fluttery body was the last thing to get crossed off the list but it too is ready to go. The truck and crane arrive early on Monday morning. It will be fun to watch this load go down the highway as we travel the sixty miles into the city to supervise the installation the same day.