Burr Arch Covered Bridge: Almost Finished

On May the fifth, our painters were onsite and the final touches were setting the stage for the first traffic to travel across the bridge.  At this point, I was slightly saddened to see the end of the project.  It has truly been a wonderful opportunity and I would gladly accept another!  I would like to thank Mr. Paul Smiddy for placing his faith in my abilities to build this bridge.  Most of all, I would like to thank God above for blessing me with the ability to do such work!

Live at Five Covers the Burr Arch Covered Bridge on Local Television News

Tonight on Live at Five, Russell Biven  did a great job of covering the story that we have been sharing here, here, and here. As you can see in the video, the roofers are hammering in the final pieces of slate.  With a few final  touches, the bridge will be done.  During filming, Jeremy said that he will be finishing the Part IV of the bridge installment soon, so check back for the latest updates.

Burr Arch Covered Bridge: Installing the Famed Burr Arches

That time had finally arrived!  It was time to install the arches.  So much time and heart had gone into the arches that it was exciting to see a reward soon coming.  The timbers proved more difficult than I had anticipated.  They had now been off the form for more than a month and had been stored outdoor the entire time.  While installing the first arch, we found that the first one had sprung in the last three feet of the timber.  This in turn pushed up the tangent point that was established on the drawings.  I wanted to do keep the arches as much as a true arc as possible.  We forced some of the spring back and eliminated nearly all of the error.  We then used the forklift to place a load onto the arches and bolted them.  This created upward thrust from the arches to the panel posts, and in essence, placed most of the load onto the arches.  After a couple of days of hard work, all the arches were installed and load bearing!  This was the pinnacle of the project.

Burr Arch Covered Bridge

While we were tailoring the final quirks of the project, Dennis and Brian started to build the wing walls of the abutments with river stone.  The roofing crew was soon to come and during this phase was when channel ten filmed for their live at five show.

Burr Arch Covered Bridge: Installing the Roof

Naturally, the next phase would be the roof system.  We used 2x6 white oak rafters and in short order, the roof was framed.  We sheathed and temporary roofed it until the day the bridge would receive its final shingles.

Roof System

Burr Arch Covered Bridge: Next was the Road Bed

Work continued to move along swiftly and without any serious complications which pleased me greatly. I was beginning to see the vision reach it’s fruition.

Beginning the roadbed

We temporarily installed the flooring on each end which was going to be removed so we could later install the arches.  We then assembled a run of scaffolding the length of the bridge and started installing the upper chords.  The upper chords contained the longest straight members of the entire bridge; the longest being nineteen feet.

Once the upper chords were installed we prepared the tie beams which contained many mortises each. They were mortised for the knee braces and also for the lateral bracing. These members were surely the most difficult to part of installation up to this point. Aligning the knee braces and upper chords all at once proved a small trial.

Braces on The King Posts

On March the 29th , I decided to remove the false work under the bridge and let the kingpost structure support itself for a while before installing the arches.  This was a mile marker of the job as we removed all but one support under each truss.  I used a sledge hammer and after a couple of small hits, the blocks were removed…and the bridge was on its own.  She spoke not a word!



Burr Arch Covered Bridge: Installing Posts

After a couple weeks of timber preparation, we started relocating the timbers from our yard to the bridge location. On 3-08-07, we placed the false work that would support the bridge until that day that it would support itself. The first timbers to be placed were the South side bottom chord members.

Site Work on The Farm at Tralee Covered bridge

I had prepared shop drawings for eight tie brackets that would hold fast the bridge to the abutments which I employed Towe Iron Works to manufacture.  This was one of the few variances from what I saw in the historic spans of which many had no means of securing to the foundation.

After we had placed the inside beam of both bottom chord runs, we were ready to install the panel posts.  In order to install these safely, we drilled a ¾ inch hole in the top section , ran a bolt through, and screwed eyelets on each end to receive the lifting straps.  This worked superbly, keeping the crew safe and also allowed us to lift the post perfectly plumb.  This section of the work went swiftly and within a week’s time we had all panel posts lifted into place and braced. 

Bridge with all Posts in place

Barracksville Covered Bridge: Getting Inspiration

During the first week of March, I went to visit my wife’s parents in West Virginia to get a closer look at some covered bridges.  They live near a fabulous work of art, the Barracksville covered bridge, built by famed bridge builder Lemeux Chenoweth.  In all, my father-in-law and I visited five covered bridge on my learning excursion.


Barracksville Covered Bridge

Burr Arch Covered Bridge: Preparing the Panel Posts

Our first order of timbers arrived on 2-20-07 and we wasted no time on laying out and prepping them.  The green white oak soon spoke as we worked at moving these giant timbers around.  I had seen a log roller at a local antique mall and purchased it for ten dollars.  It soon paid us back exponentially since we could hardly budge the timbers with manpower alone.  Our timber orders came in a way that was difficult to complete any one area of the bridge since the logs were so large our sawyer was having a difficult time locating some of the longer logs.

Mortised Timber

The first panel post is ready to install.

Burr Arch Covered Bridge: Testing the Forms

The first arch was ready to be removed from the form after three days of work but remained until I was able to have a forklift delivered.  The beam reacted superbly when it was lifted, keeping its form quite well and no cracking was herd.  On February 21st we placed the beam on benches for prep.

Moving Burr Arch From Workshop

Getting the arc lengths , joint locations and general layout was part of the fun of this job!  I have truly enjoyed the challenges.

Diagram of Beams

Burr Arch Covered Bridge: Laminating the Arches and Setting up Shop

I hired Mr. Kelley Hunter to help with building these massive arches on Monday, February 5th.  Kelley and Adam started setting up shop in the hay storage shed on-site.  I helped them along with getting the form built and my mind was jumping with anticipation as I could see those arches in my head even more clearly now that the form was ready to go!  When we started milling lumber we soon realized that our power source was inadequate so we used the help of a fine electrician, Mr. Ken, and he set us up nicely to continue full steam ahead.

After what seemed to be endless preparation on our shop, we finally were ready to begin lamination of the arches.  We had made a makeshift clamping system and on Wednesday, February 14th, it was finally tested and we had our first two laminations glued and clamped.  There was a sense of excitement and anticipation as we saw the oak being placed on the form.  A little more tweaking and the system was ready for full production.

The arches, when complete, will reach a mere 48 feet and four inches.  With four arches total, we have a total of  193 feet and four inches of arch to laminate.  There will be over 3200 lineal feet of 1 X 8 red oak totaling around 8000 pounds of oak arches!  We are using 16 laminations to reach our 12 inch thickness.


The first arch was ready to be removed from the form after three days of work but remained until I was able to have a forklift delivered on-site.  The beam reacted superbly when it was lifted, keeping its form quite well and no cracking was herd.  On February the twenty first, we placed the beam on benches for prep.

Burr Arch Covered Bridge: Pouring the Foundation of Abutments at The Farm at Tralee

On January 15th, I began my employment with Mr. Smiddy to build the bridge.  I made my office at a table in the Blount county library.  My mind was finally able to eject some of what was built up in it over that last six months.  I was actually putting on paper a bridge all my own, well, and Mr. Smiddy’s.

For two days I brainstormed and drew, brainstormed and drew.  After two and a half days, I was finished with the main body of drawings minus details.

I started work at the job site on January 18th where Paul had his men already preparing the site.  Mr. Mike Duncan was to be the Lead Carpenter on the Bridge Abutment form-work with Mr. Ronnie Duncan and soon to follow, Mr. Adam Griffith, as the rest of the carpentry crew.

Pouring concrete foundation for Burr Arch Covered Bridge January 2007

We poured footers on Thursday, January the 25th.  I ordered a pump truck to reach the far footer and we poured 32 yard of concrete, 4000lb. Pump mix.  The pump truck was two hours late but all in all things went well.


The Origin of My Passion for the Burr Arch Covered Bridge

The project started , in reality, in the Summer of 2006.  The Barlow summer vacation started the twist of fate with a beautiful location of Turkey Run State Park in Parke county Indiana.  Parke county, the covered bridge capital of the world, struck my interest in covered bridges without any knowledge of the future project.

The family and I traveled over one covered bridge after another.  I was amazed at the dates of these tunneled spans, driving over a timber framed bridge that was built in the 1850’s.  The size of the timbers impressed me giving a sense of strength and stability as we drove through the Klickity Clack caves. There was one part of these bridges that stood above all the rest in my mind and that was those wonderfully crafted “Burr” arches.  I was sure of one thing…..I was going to build a Burr Arch covered bridge, whether it be for someone else or for myself. 

This began my intense drive  for the knowledge of the covered bridges.  My wife was wonderful in buying me books for my birthday and for Christmas and I was searching frantically for any analytical information that I could round up over the net.  My goldmine was found!  I had read in a covered bridge book by Richard Sanders Allan that the Library of congress was full of historical information.  There it was, actual blueprints of even some of  the bridges that we had crossed in Indiana.  I searched over many drawings and accumulated information for the bridge that I wanted to build.  I had looked at blueprints so much that I felt I could nearly build one out of my head.

I had worked the idea of building a covered bridge so high up in my head that I was telling everyone that I was going to build one, knowing full well that I hadn’t anyone to build it for….yet!

I remember that day well.  I was trying to figure out the answering machine for my cell phone and finally retrieved my messages, some from two months before.  After going through one message after another, Mr. Paul Smiddy’s voice rang “CAN YOU SAY COVERED BRIDGE!.”  My wife attacked me; I wasn’t sure who was more excited, me or her (my cell phone was on speakerphone).  Within two weeks I was preparing foundation drawings.

Foundation Drawings for Burr Arch Covered Bridge