HOW A HAND PACKED FENCE IS BUILT          Back

 

The steps outlined below show how a typical hand-packed brush fence is built, from removal of the existing fence to setting out and fitting posts, concrete base, wiring, brush and roll top.

Most contractors undertake the work in a similar way, but the end result can vary enormously in quality, depending on the experience of the contractor, the quality of brush and the ability of the brush packers.

It takes skilled tradesmen and good quality brush to produce a fence with a fine finish, minimal maintenance and a long life.

1.    Site Preparation

Typically there will be preparation work required to clear the fence line prior to fence erection.  Existing fences will need to be cleared including removal of the old posts, rails and cladding and trimming of tree limbs and shrubs.  Sometimes an old concrete base will need to be removed, sometimes it can be re-used or used as a sub-base to the new base.

Click on images to enlarge and the 'back button to return!

Brush old timber posted fence2.jpg Cutting the Old Wiring
Brush new Speck old fence dropped1.jpg Clear the Fence Line
 

Often there is considerable work in preparing a site and even tip fees can be a significant cost factor.  These costs are additional to the quoted metre rates.  Two 6 metre trailer loads of old brush, posts and concrete and tree limbs were generated by this 50 metre long corner fence, costing $80 in tip fees and $180 in labour.

Where a brush fence is to be fitted to the top of a masonry wall or existing concrete foundation, concrete core drilling may be required or dog leg posts may need to be fitted.  Typically core drilling contractors charge about a dollar a centimetre, or about $30 per hole.

 
Brush removing old base1.jpg Removing the Old Base
Brush new Speck clearing rubbish1.jpg and Stacking
The fence depicted in this page was an old timber posted fence in the order of  40 to 50 years old.  The posts had rotted out beneath ground level many years ago and even the timbers stubs used many years after the fence was built to support the rotted posts, had rotted themselves.  The concrete base while substantial, had moved over the years and needed to be replaced.

The old fence panels are removed prior to being taken to the tip.

 
Brush new Speck clearing rubbish2.jpg Stacking the Rubbish
Brush new Speck ute load of formwork.jpg Gear to the Job
Considerable materials need to be brought to a job, including posts, formwork, pins, sand metal and cement and hand tools and barrow etc.

 

2.    Setting the Alignment & Posts

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Brush new Speck cleared fence line1.jpg Fence Line is Cleared
Brush new setting out2.jpg Setting Alignment
When the site has been cleared, the fence alignment is determined and the end posts set.

The balance of the post holes are then dug 600mm deep to a stringline at 2.4 metre spacings or less.
Brush new digging holes1.jpg Hole Digging
Brush new setting posts2.jpg ( Setting the Posts
 Click on images to enlarge!

 

3.    Setting the Formwork & Pouring the Base

Once all the posts, including any gate posts, have been set using hand mixed concrete, the top line is adjusted/fine tuned to best suit the location and, the formwork is then laid out.  Setting out and getting the correct top line to suit the location and adjoining structures is one of the most important aspects of the job, requiring skill and experience.
Brush new boxing up3.jpg Forming Up
Brush new boxing up 4.jpg Forming Up
 

The formwork is wired up and checked prior to 20/80 readymix concrete being poured.
Brush new formed up3.jpg Pinning the Formwork
Brush new pouring concrete1.jpg Readymix is Poured
 Click on images to enlarge!

Reinforcing rod (Y12) is pushed into the wet concrete, the boards are knocked/vibrated with hammers to remove entrained air and then the surface is finished.  Adelaide Brush fits steel reinforcing rod to all its bases, although there are few other contractors past or present that do so.  Due to the small 150x150mm base cross-section, the reinforcing won't stop cracking due to tree root damage, but it will stop the base from falling apart.
Brush new concrete pour1.jpg Reinforce and Pour and
Brush new concrete finishing1.jpg Finish
Concrete finishing to the top surface texture is not critical as the brush covers it, but the lines of the base edges are important to get straight in both planes.

 

4.    Fitting the Rails, Wiring Up and Packing

 
brush new wiring up1.jpg Fitting Rails/Wiring
The posts are marked ready for wiring up and the internal 'spreader' rails are cut and fitted.  The fence is then wired up in three or four bay sections using 7 wires for an 1.8 metre fence.

Click on images to enlarge! 
brush new26.jpg Brush Packing
  Brush new packing6.jpg Brush Packing
brush69.jpg   Brush Packing
brush63.jpg   Brush Packing
Click on images to enlarge!
brush new packing 7.jpg Packing
 brush65.jpg
The brush is then packed to a high density (no daylight) level of finish, with a top tradesman completing about two to three panels (5 to 7 metres) in a normal working day.  The bottoms are cut with hand shears as the packing progresses.

 
brush pinning1.jpg Fitting Wire Clips
brush pinning2.jpg Pinning
Wire pins (clips) are fitted through the fence at intervals of about 350mm, clamping the brush layers tightly together.  It is important that clips are very tight and spaced no more than the above measure, to prevent sag.

 
 brushtrimming bottoms1.jpg Cutting the Bottoms
 brushtrimming tops1.jpg Cutting the Brush Tops
When all the packing is complete and post rolls completed, the top of the fence is cut and wires fitted preparatory to the fitting of the brush roll top.

 

5.    Fitting the Post Rolls & Brush Roll Top (or steel capping)

   Fitting Post Rolls
 brush new wires prepared for roll top.jpg Fitting the Roll Wires

Click on images to enlarge!
 brush new fitting roll top1.jpg
Brush new fitting rolltop 2.jpg   the Roll Top
The roll top requires very experienced tradesmen and the pick of the brush to get the best results.  Many packers are unable to do a good 'roll'.

 

6.    Fitting Accessories & Finishing

 
brush new blue snr3.jpg Fitting Accessories
brush new Speck109.jpg   Finished Job
Accessories such as letterboxes and gates are then fitted and the job is cleaned up.

 

7.    Cleanup & Removal of Offcuts to the Tip

Typically a 50 metre fence such as the one depicted above will generate a large volume of offcuts, taking one man about two hours to clean up and about $40 in tip fees which is included in the normal metre rate.

Click on images to enlarge!
brush new rubbish1.jpg   Offcuts are loaded and .....
   rubbish tip 2.jpg

 

....  Offloaded at  the Tip                

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©  Copyright 1998;     Adelaide Brush, Fairview Park,  South Australia  5126;  Tel +61 8 82513309,  Fax. +61 8 82893155, Mobile 0418 841 889.