Preparing to Backfill and to Shoot More Shotcrete

It was extremely busy today as we are preparing to backfill our excavation and getting ready for our final shoot of shotcrete on Thursday, April 30.

Our project site is extremely cramped due to the OSHA cuts that were excavated for the front and back concrete foundation retaining walls.  Since these foundation walls are now to strength, we can backfill and compact the soil to fill the excavation.  This will provide much-needed real estate at the front of the project site.

The decision yesterday to complete the feature concrete wall in the dining room required additional scaffolding and accelerating part of the schedule.

It is all good. 

Forming the Feature Concrete Wall in Our Dining Room

After the scaffolding arrived, Bill Brown’s team started forming the feature concrete wall in the dining room.

Forming the back of the feature concrete wall in our Dining Room.

Forming the back of the feature concrete wall in our Dining Room.

 

Finding Virgin, Native Soil to Backfill Our Excavation

If our site had sufficient space, we could have excavated the OSHA cuts and stored the soil while the retaining walls were being completed.  Since we didn’t have the real estate, we exported the dirt and now we need soil to backfill our excavation.

When we were in Roatan, we discussed our backfill requirements with Lynn and Jim, who are currently building their new home on Reservoir Road in Los Gatos.  Lynn had stockpiled 10 truckloads of native soil on her project site and offered it to us.  We accepted.

Our soils report stated that ‘Should import soil be required, a sample should be approved by our office prior to its delivery to the site.’  Our soils engineer, Jerry Freeman, had been engaged to review drainage at the O’Brien property on Reservoir Road so he was familiar with the soil.  He approved of its use as backfill material for our project.

Also, our soils report stated, ‘. . . and compacted to a density equivalent to at least 90% of the maximum dry density of the soil according to ASTM D1557.’

Since Jerry couldn’t observe the soils compaction, we engaged HP Inspections to observe the compaction.  They required a sample of the soil from Reservoir Road to be delivered to their offices so they could establish the maximum dry density of the soil.

Bryan headed to Reservoir Road.

Stockpile of soil on Reservoir Road.

Stockpile of soil on Reservoir Road.

10 kloads of native soil, ready for tucking to Via Sereno.

10 loads of native soil, ready for trucking to Via Sereno.

Sampling the soil for testing by HP Inspections.

Sampling the soil for testing by HP Inspections.

Confirming the Reinforcing Steel Layout

In preparing for our final shoot of shotcrete, we will need to have the reinforcing steel (rebar) inspected by the City of Monte Sereno.  Our structural engineers need to verify that the rebar will meet their design requirements. 

To simplify matters and make it easy for everyone, we took digital photos of the actual rebar in place today and then spoke with Thien Doan (Duquette Engineering) and Shane Lothrop (Innovative Structural Engineering) to confirm the rebar met their design requirements.

Our interior concrete wall by the Kitchen has five openings and we need rebar around each opening.

View of wall to be shotcreted on April 30.  Note the five openings in the wall (Pantry Door, Storage Door, HVAC, Garage Door and TV Niche).

View of wall to be shotcreted on April 30. Note the five openings in the wall (Pantry Door, Storage Door, HVAC, Garage Door and TV Niche).

The profile of the concrete wall is set out on detail 2 on this sheet (SK-1).

This wall will be shotcreted on Thursday, April 30 so we are preparing it now.

Pantry Door

Rebar under the Pantry door.

Rebar under the Pantry door.

Top left of the Pantry door.

Top left of the Pantry door.

Storage Door

Top right of Storage door.

Top right of Storage door.

Top left of Storage door.

Top left of Storage door.

Bottom left of Storage door.

Bottom left of Storage door.

Bottom right of Storage door.

Bottom right of Storage door.

HVAC

Right side of HVAC over Storage door.  Note that a beam pocket will go in the space without rebar in place.

Right side of HVAC over Storage door. Note that a beam pocket will go in the space without rebar in place.

Right side of HVAC and below Garage door.

Right side of HVAC and below Garage door.

Garage Door

Bottom left of Garage door, above HVAC.

Bottom left of Garage door, above HVAC.

Top left of Garage door.

Top left of Garage door.

Top right of Garage Door.  Note form over Garage door will be completed.

Top right of Garage Door. Note form over Garage door will be completed.

TV Niche

Top left of TV Niche.

Top left of TV Niche.

Top right of TV Niche.

Top right of TV Niche.

Bottom right of TV Niche.

Bottom right of TV Niche.

Bottom left of TV Niche.

Bottom left of TV Niche.

Shane Lothrop was fine with the rebar placement.

After reviewing the layout with Steve Duquette, Thien sent an e-mail stating that they require two more diagonal bars around the upper right coner of the HVAC opening.

No problem.

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