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Burn Shield Design

by Larry Sweeny & Todd D’Amario,
Outrageous Constructions

Outrageous Constructions

Outrageous Constructions designed and built a burn shield for the Anno Domino installation at Burning Man 2000. Our primary concern was achieving a reasonable level of playa protection while creating a foundation strong enough to support the weight of the AD2K Domino Tower - a 30' tall burn structure - as well as that of any people walking on the shield. Cost and asthetics were also important factors.

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After reviewing several possible construction techniques and materials, we settled on a 16' square wooden frame covered with 1/2" OSB. OSB, or Oriented Strand Board, is similar to plywood but costs about 2/3 less. To prevent the wooden frame from catching fire, we covered it with .28 gauge sheet metal.. (Had we not needed a flat surface upon which to build our burn structure, we might have used corrugated metal instead.) The shield's dimensions were determined by the size of our burn structure and the manner in which we expected it to collapse, as well as for conservation of materials (it used an even amount of 4' x 8' lumber).

This is by no means the only method of building a burn shield, but simply what worked well for us. Our shield was (relatively) inexpensive, quick to assemble and provided enough protection that, with minimal clean up, we were able to leave no trace.


Building the Frame

We first laid six full length (96") 2'x 4's horizontally (Fig. A - white lines).

To make the interior "joists" we then cut the remaining twenty-six 2' x 4's down to a length of 93.75". Four of these pieces became the outer edges of the frame, and two were placed at the frame's center, 96" in (Fig. A - blue lines).

Because we needed the platform to support a significant load without flexing, the remaining joists were laid 16" on-center (Fig. A - red lines). Otherwise, a distance of 24" on-center or more would have been adequate.

Notice that while the central and side beams were laid directly opposite one another to provide support at the edges of the OSB, the joists were offset from each other (Fig. A - Detail). This minimized the amount of toenailing, a situation in which nails must be hammered in at 45 degree angles, rather than straight on (Fig. B).

The frame was assembled with 16d framing nails, as used in standard residential construction. Screws or joist hangers could also easily have been used. As a final step, we glued small "bricks" (made of 2' x 4' scraps) every 4' along the underside of the central and exterior studs (Fig. C - orange squares). This elevated the frame, increasing airflow and reducing frame-to-playa contact.


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Laying the OSB

All eight sheets of OSB were placed on the frame and squared up before nailing (Fig. D).We used 8d nails to secure each sheet to the frame.

The Metal Surface

The eight 4' x 10' pieces of sheet metal were then laid on top of the OSB crossways and nailed in place (Fig. E). Since each sheet was 2' longer in one dimension than the OSB it covered, we overlapped the metal in the center slightly and folded the excess down the sides of the base.

 

Results

The Domino Tower was burned on Saturday night, after the Man. Despite high winds, it collapsed as planned: one story at a time, straight down, falling entirely within the area covered by the burn shield. Despite our remote location, the resulting bonfire subsequently became the (unexpected) recipient of additional fuel from other Burning Man participants, including the BM pyro crew. As a result, it burned through the night and into the following morning. Also, due to the extremely high winds, flames from several of the burning dominoes that were toppled into the tower to ignite it were blown under the shield. This resulted in a portion of the shield's wooden frame burning underneath the metal, something that might have been prevented by shielding all four sides of the frame instead of merely two. Even so, the metal itself never burned through, significantly reducing impact on the playa and minimizing our post-burn clean up.

What scarring there was occured in areas that were subjected to high amounts of heat for a long period of time. Areas of the playa that were only briefly exposed to flame - the ground beneath the burning dominoes we toppled, for example - were essentially undamaged. In these areas, clean up was often as simple as sweeping up the ash and redistributing any discolored surface dust.

Alternatives & Improvements

Had we not needed to build such a strong platform, we probably would have constructed an all-metal shield, using metal studs rather than 2' x 4's. Corrugated metal would also provide more insulation than sheet metal, especially if multiple layers (laid perpendicularly) were used.

If cost were not an issue, more protection could be also have been obtained by making a "double-decker" shield, with two layers of framing.

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Another possibility is the inclusion of burn blankets and/or sand below the frame. Sand is cheaper, though harder to clean up than burn blankets. Regular blankets (non-synthetic only please) soaked with water can also be pressed into service as insulation. Don't go overboard with water though; it's a LOT easier to sweep up ash and debris than it is to dig it out of hardened playa mud.

Regardless of what methods you use, be sure to LEAVE NO TRACE.

Materials

Item Quantity Cost Each Total Cost
8' 2' x 4' stud
32
$2.00
$64.00
4' x 8' OSB sheet
8
$7.00
$56.00
4' x 10' 28 ga. sheet metal
8
$17.50
$140.00
Misc. (incl. fasteners)
n/a
n/a
$10.00
TOTAL
$270.00

Resources

Most of the necessary materials are easy to find, but shop around for the best prices. Also, it never hurts to ask about bulk or contractor discounts. (For the latter they may require a license#, so if you have a friend who's a contractor bring them along.) If you have trouble locating sheet metal (especially in larger sizes) try HVAC (Heating, Ventilation & Air Conditioning) or plumbing supply stores. We bought our metal from:

Rubenstein Supply Company
96 Woodland Avenue
San Rafael, CA
(415) 454-1174

Other sheet metal suppliers include:

CP Sheet Metal
757 Lincoln
San Rafael, CA
(415) 453-1306

Van Bebber Brothers Inc.
729 Petaluma Blvd. South
Petaluma, CA
(707) 762-4528

Bataeff Salvage is an excellent source for all those hard to find things that you never knew you needed. If it's mechanical or industrial and disused, you can find it somewhere in Bataeff's yard.

Bataeff Salvage
244 Mountain View Avenue
Santa Rosa, CA
(707) 584-8401

Bob Stahl's website is an excellent resource for learning about burn scars, planning your burn shield, or designing other desert structures.

 

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