It’s been a busy week! Last Friday we spent the day digging two trenches to act as footings for our planned stone walls. The first will be to support a stone retaining wall to level out the new pottery site which is being built over the old orchard. With the trench dug, I ordered 9 tonnes of gravel to fill it back in. Crushed gravel cost $35 a tonne plus $50 delivery, the delivery charge works out to be $11 per tonne from Tahmoor, just 15 kms. away. I needed 2 truck loads. I spent the weekend shovelling and wheel borrowing the 9 tonnes of gravel back into the hole in 75mm. layers. Intermittently stomping, compacting and watering the layers, until I got back to ground level, to make sure that all the material was packed down very firmly. I finished that job on Monday. It seems that I’m OK with shovelling about 4 tonnes per day, before I run out of steam. I finished the last tonne on Monday. The soil that we removed went to ‘top-dress’ the old ruined pottery site, which was just a mess of rubble and broken pots and bricks.
Having considered all the options available to us and canvassed a few opinions, we have decided to raise the level at the back of the new pottery building site up 1 metre to bring it to level with the front driveway. I had originally thought that I could save money by lowering the front down and doing what is called ‘cut and fill’, where half of the site is dug down and lowered, and the soil that is removed is used to build up the back of the site. All very economical. However, this would make the front of the building below ground level and prone to flooding in extreme storms, unless we had very good perimeter drainage. I asked my friend Dave the engineer, he told me that such drainage eventually always fails.
The old pottery was built this way with the front of the building 600mm. below natural ground level. I made a contour drain out in front with a 200 mm embankment then an ‘agg’ drain below the stone retaining wall to deal with any seepage. The pottery flooded twice in its 36 years! There are rain storms big enough to override any drain and small embankment. Or so it seems.
The person that I trust most in these matters is Ross, the plant operator who is doing all the earth works for us here. He has been really helpful, fitting us in, in-between his other jobs. When I suggested the cheaper ‘cut-and-fill’ option, He shook his head and simply said to get it up above ground level. You won’t regret it.
That left me with a problem. Where would I get all the fill? I considered de-constructing the wall of the largest dam and using all that material, but I don’t really want to do that. My construction certificate says that if I bring in fill, it must be certified ‘clean’ natural material from a registered and certified quarry. So I was snookered.
I did a quick calculation that the site is 25m. x 15m. so to raise it up 1 metre at the back, would take around 300 to 400 tonnes of gravel fill. The unbelievably resourceful Ross rang around his contacts for me. Beyond belief, he managed to find a batch of 400 tonnes of ‘sub-prime’ road base, crushed gravel from a quarry. I could get the 3 to 400 tonnes for free, but I would need to pay for the cartage. Such amazing synchronicity! It’s a huge number of truck loads. The cartage will take around 4 to 5 days to complete. I’m being charged $16 per tonne delivery from the quarry, about 70 kms away. I can’t believe our luck. It’s a really good deal. I just paid $46 per tonne for the local gravel yard to bring in 2 loads of much the same thing last Saturday.
When we built the last pottery, we decided to make it out of mud bricks. The soil onsite here is very good for mud bricks, but we didn’t need or want a 100 tonne hole across our land. We hunted around and found a local small quarry that was mining sand and gravel, but there was an overburden of clay that they needed to get rid of. We could have it for free, but had to pay for the cartage. Same story, just separated 35 years in time.
So we are on our way and the site is being filled and compacted to a level just above the natural. So now I will not have to worry about flooding in extreme wet weather events. I even get a certificate from the quarry for the council inspector, guaranteeing that our fill is natural clean crushed stone as specified on our construction certificate.
Up until last week, I could never have imagined trucking 400 tonnes of anything onto this block. It still seems surreal. On Tuesday the trucks started arriving and the they are huge!
They keep on coming 3 to 4 per day over the week until on Friday, at the end of the week we have 370 tonnes in the ground and are almost there, up to ‘natural’ ground level across the site.
On Thursday, the 30 tonnes of stones arrived just after dawn. We spent all day Thursday and half of Friday lifting and lowering the huge 1.2 tonne stones into position to make the retaining wall. These stone blocks are 2 metres long by 500mm. sq. I have managed to find some ‘C’ grade seconds rejects for just over 100 dollars each. They work out to be the same cost as those huge concrete blocks that are cast using all the left-over concrete returned to the mixing plant. I tried to buy some of these, but there is a waiting list of 2 months, and then ,no guarantee that there will be any or enough of them available on the day, as it all depends on the amount of returned excess concrete that makes it’s way back to the mixing plant, and needs to be gotten rid of. By Friday afternoon the stone wall is almost complete and the ‘crushed granite fill’ that has been delivered at the rate of three x 30 tonne truck loads per day, the gravel was spread and compacted as it was delivered, in-between placing the load of large stones. Ross and I wrangle them into position over the compacted gravel trench footing. The site is almost full. We will need just another 60 tonnes to make the site completely level. That material is ordered for Monday morning.
In just one week we have completely changed the nature of our block of ground, from a sloping orchard site into a level building site with a substantial stone retaining wall.
So, after 16 tonnes, what do you get? Another day older and deeper in debt, or so the song goes. In this case it’s 400 tonnes and I get the satisfaction of seeing the site of the new pottery becoming a reality. Luckily I’m not in debt, but it has cost me about $12,000 to get back to our new elevated ground level, money well spent on this occasion.
A big thank you to Claudia Citton and Rochelle Johnson who organised the GoFundMe page that has allowed us to get going on this project while the insurance company sat on their hands.