Identity: "The Iron Breeze" | Footprint: 20' x 40' (LOCKED) | Method: Cut & Flip Hybrid
Material Inventory Strategy
Utilizing structural pipe from decommissioned sheds to build a module that matches the standard 20' x 40' footprint. Note: This size is mandatory as the 20' roofing sheets have already been purchased and staged.
1. Footage Calculations (20' x 40' Module)
~416'
Total Pipe/Lumber Needed
8
Ribs (5.7' O.C.)
~72'
Recycled (8x9' segments)
~140'
Extension Deficit (Pipe/Wood)
2. Rib Geometry (Extension Required)
The original shed width (17.5') yields rafter segments of only ~9'. To accommodate the 20' roof sheets, an 11' extension is required for every rib.
3. Structural Notes
Fixed Footprint: The 20' rafter length is non-negotiable to ensure the pre-purchased 20' roof sheets (26-gauge, 3/4" corrugated profile) provide the necessary coverage and overhang.
No Ground Pipe: To prevent corrosion and facilitate cleaning, the ground layer will not have a lengthwise pipe. Each rib-wall segment terminates in a concrete or pressure-treated footer.
Angled Peak: The original angled section of the pipe shed is used at the container anchor point to provide natural pitch without stress-bending.
Purlins: 3 lengthwise purlins (Metal pipe or 2x4 scrap) are required. The middle purlin sits ON TOP of the sleeve splice to lock the joint and provide roof sheet attachment.
Mid-Span Posts: Four structural posts are added along the 40' span (under the middle purlin/splice) to prevent sagging and support the joined rafters.
Wall Girts: Horizontal girts at 4' height are required to support the transition from hardware cloth to upper mesh.
West End Gate: A 3.5' wide x 6.5' high framed gate (Pipe or Lumber) is required at the West end, centered on the 3' aisle, swinging outwards.
Mesh Attachment: Hardware cloth will be wired directly to the pipe frame using UV-resistant ties or galvanized wire loops.