Steve Berger’s shop stands out even from a distance. The bank of clerestory windows mounted high along a wall sets his structure apart from others dotting the countryside outside Wellman, Iowa. Borrowing from American architect Frank Lloyd Wright’s ideas on passive solar heating, the 4- x 6-foot panels of glass channel morning sunlight down onto the shop floor.
To truly appreciate the planning that went into Berger’s 82- x 90-foot building, however, it’s good to note the capabilities he built into the shop that you don’t see. As he says, this shop is “a work in progress.”
Berger’s new maintenance facility occupies open ground across a gravel road and 200 feet from any other building, including the 1,600-square-foot, 1960s-era shed that once served as his primary shop. The building he erected in 2014 was intentionally sited here to be unobstructed by other buildings so the shop’s footprint can grow as new needs arise.
For example, Berger offers he may one day add an enclosed wash bay or an oil-change pit. These additions would mean pushing out the north wall and building an additional bay for either or both functions. Nothing in the area obstructs expansion.
Or, consider an open patch of grass in front of the building. One day, an office will be built there. With that in mind, Berger oversized his geothermal field to heat and cool that future space. He also has dedicated enough electrical service to operate it.
Crane Service. Similarly, the interior of the shop was designed to accommodate two functions not yet installed. The steel skeleton of the building was constructed to accommodate a 10-ton bridge crane. The crane’s hoist will move assemblies and supplies most places in the shop. “That’s why we went with 22-foot sidewalls so we can get that hook height to put a combine underneath it and still move things to it,” Berger says.
The other capability “plumbed” into the shop is a truck lift to perform engine and tire work. “We don’t have it now, but we have the flexibility to install it,” says Berger, explaining the advance planning. “This shop was built for expansion. It has flexibility for whoever has the shop in 20 to 30 years.”
That is the story of what is to come. What did Berger build for
Light is an overarching theme in the shops. Berger is a fan of natural illumination. “I don’t want to feel boxed in,” he says.
Those high panes of glass that give the shop an unusual distinction from afar bathe his workspaces in natural light. “You’re going to give up a little heating efficiency by adding those windows, but it’s a balance,” he says. “When you’re inside the shop and everything is closed up in the winter, there are enough windows to still let in that natural light [and warmth].”
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A south-facing, 46-foot-wide hydraulic door gives entrance to Berger’s largest implements--and through its double row of windows more natural light.
Berger’s choice for artificial lighting is rows of ceiling mounted, six-bulb, T5 light units. The fluorescent light sets are highly economical, long lasting and cast a visibly comfortable level of light.
More And More. Not surprisingly, Berger wanted space. “Like every farmer, we outgrew our old shop,” he says.
“We wanted a facility where we could have multiple projects going on at the same time.” That means his shop accommodates a 16-row planter torn apart for three weeks waiting for parts, plus semis and tractors.
Four overhead doors, including the large hydraulic door, give entrance to the inside of the shop. Importantly, several service doors allow Berger and others to enter the shop without having to open the larger doors. The hydraulic door creates a 20- x 46-foot covered workspace when it’s open. It opens over a concrete apron 40 feet wide and 93 feet long.
“I really value access. If you have to move something out of the shop, I don’t want to have to move everything else first,” he says.
Berger considered efficiency vital to his new building. “In my old shop, all you had to do was reach out and grab a screwdriver. But, the center of the shop floor now is at least 40 feet from any wall. You don’t want to have to walk 40 feet to pick up a wrench. It’s not efficient. Everything has to become mobile,” he says. “Everything has to come to you.”
Rolling Along. Berger is putting larger pieces of equipment on wheels. Compressed air, lubricants and power are delivered to the farthest reaches of the shop by retractable hose reels and extension cords, the latter Berger hardwired into outlet boxes around the shop. By each of the overhead doors, Berger installed a service center that conveniently includes power washing and compressed air.
The geothermal system and insulation (8 inches of foam blown into the walls) keeps the shop within a comfortable working range in winter and summer. “Probably the biggest surprise is the cooling part,” Berger says. “I’ve had 113ºF index outside. [The geothermal system] took the humidity out and cooled this space down to 80ºF.”
A cool working environment in the summer generates more working hours. “We hadn’t really considered that,” Berger notes.
Shop Do-Overs? Berger’s immediate answer to this question is even more space. “I think any farmer would say they would build it bigger.”
Also, side doors. They are now 20 feet wide. “We might have gone a little bigger. That would have given us a little more room to work.”
It’s All in the Details:
1. Light And Lift. Note the placement of windows to light the work area, in addition to overhead and highly efficient T5 fluorescent lights. The roof was engineered to accept a 10-ton bridge crane.
2. Service Center. Steve Berger installed four service stations by the shop doors. Each supplies power, water and compressed air.
3. Compressed Air. Berger’s air compressor is installed in a building separate from his shop. That compressed air is plumbed into his shop spaces and made available through a generous number of air drops installed onto the shop walls.
4. Power Extension. Here’s a great way to extend power far out into the shop while keeping the receptacle free of cords. Berger hardwired extension cords into some of his outlet boxes. The extension cords reach 50 feet out into the shop.
5. Charging Station. Charging batteries and keeping the correct battery with the right power tool can be a hassle. Berger installed an outlet strip above a line of parts boxes. The box tops make an excellent place to charge batteries and store the tools
6. Welding Beam. Berger sank grounded I-Beams into his floor. Hooks and chains can be welded to the beams for repair work.
7. Floor Drain. Slots in the floor direct wastewater to these collection boxes and then outside the shop.
8. Bending And Straightening. Berger installed anchoring points into his shop floor to help tie down equipment or provide an anchor for repairing damage to equipment.
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