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{{Template:ENGR215inprogress|April 7, 2018}}
[[File:Upcycledbenches.JPG|thumb|Final Up-cycled benches constructed for Zane Middle School.]]


==Abstract==
{{Project data
''One paragraph summary of your project from background to discussion and next steps.''
| status = Deployed
| authors = Team FMLD, User:Fiona Roper, User:Alb26, User:Lyarbrou, User:Tjc406
| cost = USD 546.56
}}


There should be an image near the top.  
{{Device data}}
 
The purpose of this project is to create up-cycled benches used for sitting purposes, campus beautification, and for educating both students and faculty about the recyclable use of material waste in the community. While many options were considered for building the benches, street signs and a metal frame were decided upon for aesthetic reasons and that they would be up-cycled. The resulting benches are made of galvanized steel plumbing pipes and up-cycled street signs. The benches are comfortable, functional, and educational.


== Background ==
== Background ==


Catherine L. Zane Middle School in Eureka, CA, is the client entity for the up-cycled benches. The
school focuses on science, math, engineering, art, and technology and is made up of 600
students, grades six through eight, of varying backgrounds.  Our client representative is Trevor
Hammons.
== Problem Statement and Criteria ==
Team FMLD's objective is to create upcycled benches used for educating both students and faculty about the recyclable use of material waste in the community, campus beautification, and for sitting purposes.
{| class="wikitable"
! Criteria
! Weight
|-
| Safety
| 10
|-
| Durability
| 9
|-
| Cost
| 7
|-
| Aesthetics
| 7
|-
| Level of upcycle
| 6
|}
== Description of Final Project ==


== Problem statement and criteria ==
The final design for the Up-cycled Benches consist of aluminum street signs attached to a metal frame. The main materials used were selected to demonstrate re-purposing of materials through "up-cycling".
Use sortable table.
The metal frame for both benches was made from ¾" galvanized plumbing pipe. Custom cut pipes fit the length and width of the street signs. The pipes were connected using "T" and "90 degree" connectors and flanges the middle bars that make up the seat of the benches.


== Description of final project ==
In the case of the middle bars, each side was tightened only half way because there cannot be a closed loop unless special connectors or backwards threading is used. To improve the strength of the bench and the half tightened bars, each joint is welded on either side as depicted in Figure 5 below. The signs are attached in multiple ways. The attachments can be seen in Figure 4 below. The signs that make up the seats are attached using pipe straps for the back two bars of the frame and bolted through the pipe on the front bar. The seat signs are recessed to create a smoother edge for the user to hang their legs over. The signs that make up the back of the bench are bolted through the pipe frame in multiple spots instead of using pipe straps.
Photos and descriptions. Use gallery.


Include a how to use and maintain section. See the how to template below.
<gallery>
| Image:Side by side.jpg| Figure 1: Both finished benches side by side.
| Image:No Parking bench.jpg| Figure 2: Finished No Parking bench.
| Image:Bike Bench Fin.jpg| Figure 3: Finished Bike Lane bench.
| Image:Underside bench.jpg| Figure 4: Underside of one of the benches showing the various attachment methods used.
| Image:T joint.jpg| Figure 5: Welded T joint sprayed with Cold Galvanizing Compound to prevent rust.
</gallery>


[[File:Proto 1.jpg]]===Prototyping===
=== Prototyping ===


Use a gallery of prototyping photos and lessons learned.
Figure 6 shows our first prototype. This prototype helped us to figure out the layout of the signs and that the Bike Lane signs needed to be raised to create a more comfortable back support. Figure 7 shows a small scale of the Bike Lane Bench. This prototype helped us to roughly figure out how the frame of the bench would fit with the signs. Figure 8 is an AutoCAD drawing of one of the benches. This prototype contained the actual dimensions of the pipes we would be using. Figure 9 shows our last prototype before building. This prototype was originally supposed to be the beginning of the final product but in building we learned that when making a closed loop with piping, a special connector or backwards threads are needed. This lead us to our decision to weld the joints.
 
<gallery>
| Image:Proto 1.jpg| Figure 6: First prototype of Bike Lane bench.
| Image:Bike Bench pro.jpg| Figure 7: Small scale prototype of Bike Lane bench.
| Image:FMLDbenchesACAD.jpg| Figure 8: AutoCAD of bench including dimensions.
| Image:Lauren pipe.jpg| Figure 9: Lauren Yarbrough prototyping how the pipes and joints fit together for the bench frame.
</gallery>


=== Costs ===
=== Costs ===
{| class="wikitable sortable"
 
! Quantity !! Material !! Source !! Cost ($) !! Total ($)
The itemized summary of costs to construct the bench are listed below.
 
{| class="wikitable"
! Quantity
! Material
! Cost ($)
! Retail Total ($)
! Team FMLD Total ($)
|-
| 22
| Custom cut 3/4" galvanized pipe
| 166.25
| 166.25
| 166.25
|-
| 10
| 3/4"x 1 1/2" galvanized nipple
| 1.39
| 13.90
| 13.90
|-
| 10
| 3/4"x 6" galvanized nipple
| 2.79
| 27.90
| 27.90
|-
| 20
| 3/4" Ts
| 3.89
| 77.80
| 77.80
|-
| 8
| 3/4" 90s
| 2.29
| 18.32
| 18.32
|-
| 8
| 3/4" Flanges
| 6.99
| 55.92
| 55.92
|-
| 8
| Street Signs
| 38.75
| 38.75
| 38.75
|-
| 1
| Cold Galvanizing Compound Spray
| 8.47
| 8.47
| 0.00
|-
| 3
| Pipe Strap (Packs of 10)
| 1.49
| 4.47
| 0.00
|-
| 2
| Drill bit
| 4.99
| 9.98
| 0.00
|-
| 60
| Various screws (stainless)
| Varied
| 54.94
| 0.00
|-
|-
| 3 || Things || The Thing Store
| 65
|align="right"| 2.20
| Various nuts (stainless)
|align="right"| 6.60
| Varied
|-  
| 27.64
| 1 || Another thing - 3' x 2', Yellow|| The OT Store
| 0.00
|align="right"| 240.00
|-
|align="right"| 240.00
| 130
|-class="sortbottom"
| Various washers (stainless)
|colspan="4" align="right" | '''Total Cost'''
| Varied
|align="right"| '''$246.60'''
| 7.02
| 0.00
|- class="sortbottom"
! colspan="4"|Retail Total (with tax)
! $546.56
|- class="sortbottom"
! colspan="4"|Team FMLD Total
! $400.00
|}
|}


==Testing Results==
== Testing Results ==
The upcycled benches can support a number of individuals and can withstand the punishement of middle schoolers. It is currently placed at Zane Middle School.


==How to build==
The larger upcycled bench can support 600 lbs and the smaller can support 400lbs. Both products can withstand prolonged use by middle schooler students.
Use [[Template:How_to]]


== How to Build ==


== Maintenance ==
{{Step
| number = 1
| text = Measure the desired dimensions.
}}


Introduce this maintenance section.
{{Step
| number = 2
| text = Cut the right amount of pipe to reach desired dimensions. Remember to include the width of the
}}


=== Schedule ===
{{Step
| number = 3
| text = Thread the ends of the pipe so that it fits inside the T-joints and elbows.
}}
 
{{Step
| number = 4
| text = Screw in pipes to their respective joints. Note: Our team found that completing one side of the of the frame, then screwing in the pipes that connect both sides works the best, as you will back out the pipe and screw it into the other side of the frame.
}}


{{Step
| number = 5
| text = Weld the space between the joint and the pipe to secure it. This will make the bench even more sturdy.
}}


{{Step
| number = 6
| text = Drill holes in the signs where the screws will connect the signs to the bench and where the pipe straps will fasten the signs to the bench.
}}


;Every 2 years
{{Step
| number = 8
| text = Grind the remaining amount of screw as close to the washer as possible. The purpose of this step is to get rid of the unwanted screw that could catch on people, items, or clothing.
}}


*Welded joints must be sprayed with Cold Galvanizing Compound Spray to prevent rusting.
{{Step
| number = 9
| text = Spray Galvanizing Compound onto the welds, nuts, and washers to prevent rusting.
}}


== Maintenance ==


=== Instructions ===
The final design requires minimal maintenance. Cold galvanizing compound spray will need to be applied to the welded joints every 2 years to prevent rusting.


This is how to maintain. The step by step how to template {{Tl|How to}} is most likely best for this part.
=== Schedule ===


{{How to
;Every 2 years


|title=How to Do Something
* Welded joints must be sprayed with cold galvanizing compound spray to prevent rusting.


|File:Bpack bike trailer - demo 1.jpg |Backpack frame bike trailer |1 |Do something.
== Usage ==


|File:Aleiha dish.jpg |Aleiha's parabolic solar cooker |2 |Do something really complicated but made simple, etc.
Below is a video about the intended use of the benches:


}}
{{Video|https://youtu.be/2GGRJaijBGE}}


==Discussion and next steps==
== Poster ==


Below is the poster that Team FMLD created.


== Suggestions for future changes ==
[[File:FMLD Poster.jpg|thumb|none]]


This is where to lay out suggestions for how to make the project function better in the future.
== Suggestions for Future Changes ==


In the future, using recycled pipe would increase the level of up-cycle of the benches. Another change to the benches could be using couplers so no welding is required because welding galvanized pipe is dangerous and strips the galvanized coating from the metal.


==References==
{{Page data
See [[Help:Footnotes]] for more.
| part-of = Engr205 Introduction to Design
{{Reflist}}
| keywords = Upcycling, Furniture, Fabrication, Metal Working
| organizations = Zane Middle School, Cal Poly Humboldt
| sdg = SDG11 Sustainable cities and communities
}}


[[Category:Engr215 Introduction to Design]]
[[Category:Upcycling]]
[[Category:Furniture]]
[[Category:Fabrication]]

Latest revision as of 16:54, 28 February 2024

Final Up-cycled benches constructed for Zane Middle School.
FA info icon.svg Angle down icon.svg Project data
Authors Team FMLD
Fiona Roper
Andrew Barron
Lauren Yarbrough
Tyler James Caseltine
Status Deployed
Cost USD 546.56
OKH Manifest Download
FA info icon.svg Angle down icon.svg Device data
Hardware license CERN-OHL-S
Certifications Start OSHWA certification

The purpose of this project is to create up-cycled benches used for sitting purposes, campus beautification, and for educating both students and faculty about the recyclable use of material waste in the community. While many options were considered for building the benches, street signs and a metal frame were decided upon for aesthetic reasons and that they would be up-cycled. The resulting benches are made of galvanized steel plumbing pipes and up-cycled street signs. The benches are comfortable, functional, and educational.

Background[edit | edit source]

Catherine L. Zane Middle School in Eureka, CA, is the client entity for the up-cycled benches. The school focuses on science, math, engineering, art, and technology and is made up of 600 students, grades six through eight, of varying backgrounds.  Our client representative is Trevor Hammons.

Problem Statement and Criteria[edit | edit source]

Team FMLD's objective is to create upcycled benches used for educating both students and faculty about the recyclable use of material waste in the community, campus beautification, and for sitting purposes.

Criteria Weight
Safety 10
Durability 9
Cost 7
Aesthetics 7
Level of upcycle 6

Description of Final Project[edit | edit source]

The final design for the Up-cycled Benches consist of aluminum street signs attached to a metal frame. The main materials used were selected to demonstrate re-purposing of materials through "up-cycling". The metal frame for both benches was made from ¾" galvanized plumbing pipe. Custom cut pipes fit the length and width of the street signs. The pipes were connected using "T" and "90 degree" connectors and flanges the middle bars that make up the seat of the benches.

In the case of the middle bars, each side was tightened only half way because there cannot be a closed loop unless special connectors or backwards threading is used. To improve the strength of the bench and the half tightened bars, each joint is welded on either side as depicted in Figure 5 below. The signs are attached in multiple ways. The attachments can be seen in Figure 4 below. The signs that make up the seats are attached using pipe straps for the back two bars of the frame and bolted through the pipe on the front bar. The seat signs are recessed to create a smoother edge for the user to hang their legs over. The signs that make up the back of the bench are bolted through the pipe frame in multiple spots instead of using pipe straps.

Prototyping[edit | edit source]

Figure 6 shows our first prototype. This prototype helped us to figure out the layout of the signs and that the Bike Lane signs needed to be raised to create a more comfortable back support. Figure 7 shows a small scale of the Bike Lane Bench. This prototype helped us to roughly figure out how the frame of the bench would fit with the signs. Figure 8 is an AutoCAD drawing of one of the benches. This prototype contained the actual dimensions of the pipes we would be using. Figure 9 shows our last prototype before building. This prototype was originally supposed to be the beginning of the final product but in building we learned that when making a closed loop with piping, a special connector or backwards threads are needed. This lead us to our decision to weld the joints.

Costs[edit | edit source]

The itemized summary of costs to construct the bench are listed below.

Quantity Material Cost ($) Retail Total ($) Team FMLD Total ($)
22 Custom cut 3/4" galvanized pipe 166.25 166.25 166.25
10 3/4"x 1 1/2" galvanized nipple 1.39 13.90 13.90
10 3/4"x 6" galvanized nipple 2.79 27.90 27.90
20 3/4" Ts 3.89 77.80 77.80
8 3/4" 90s 2.29 18.32 18.32
8 3/4" Flanges 6.99 55.92 55.92
8 Street Signs 38.75 38.75 38.75
1 Cold Galvanizing Compound Spray 8.47 8.47 0.00
3 Pipe Strap (Packs of 10) 1.49 4.47 0.00
2 Drill bit 4.99 9.98 0.00
60 Various screws (stainless) Varied 54.94 0.00
65 Various nuts (stainless) Varied 27.64 0.00
130 Various washers (stainless) Varied 7.02 0.00
Retail Total (with tax) $546.56
Team FMLD Total $400.00

Testing Results[edit | edit source]

The larger upcycled bench can support 600 lbs and the smaller can support 400lbs. Both products can withstand prolonged use by middle schooler students.

How to Build[edit | edit source]

1

Measure the desired dimensions.

2

Cut the right amount of pipe to reach desired dimensions. Remember to include the width of the

3

Thread the ends of the pipe so that it fits inside the T-joints and elbows.

4

Screw in pipes to their respective joints. Note: Our team found that completing one side of the of the frame, then screwing in the pipes that connect both sides works the best, as you will back out the pipe and screw it into the other side of the frame.

5

Weld the space between the joint and the pipe to secure it. This will make the bench even more sturdy.

6

Drill holes in the signs where the screws will connect the signs to the bench and where the pipe straps will fasten the signs to the bench.

8

Grind the remaining amount of screw as close to the washer as possible. The purpose of this step is to get rid of the unwanted screw that could catch on people, items, or clothing.

9

Spray Galvanizing Compound onto the welds, nuts, and washers to prevent rusting.

Maintenance[edit | edit source]

The final design requires minimal maintenance. Cold galvanizing compound spray will need to be applied to the welded joints every 2 years to prevent rusting.

Schedule[edit | edit source]

Every 2 years
  • Welded joints must be sprayed with cold galvanizing compound spray to prevent rusting.

Usage[edit | edit source]

Below is a video about the intended use of the benches:

mqdefault.jpgYouTube_icon.svg

Poster[edit | edit source]

Below is the poster that Team FMLD created.

FMLD Poster.jpg

Suggestions for Future Changes[edit | edit source]

In the future, using recycled pipe would increase the level of up-cycle of the benches. Another change to the benches could be using couplers so no welding is required because welding galvanized pipe is dangerous and strips the galvanized coating from the metal.

FA info icon.svg Angle down icon.svg Page data
Part of Engr205 Introduction to Design
Keywords upcycling, furniture, fabrication, metal working
SDG SDG11 Sustainable cities and communities
Authors Fiona Roper, Andrew Barron, Lauren Yarbrough
License CC-BY-SA-3.0
Organizations Zane Middle School, Cal Poly Humboldt
Language English (en)
Related 0 subpages, 5 pages link here
Aliases ZaneMiddle upcycled benches
Impact 774 page views
Created April 25, 2018 by Fiona Roper
Modified February 28, 2024 by Felipe Schenone
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