We placed 48 hollow core concrete panels this morning.  The first panel was lifted from the truck at 8:10 am and the last panel was put in place less than 4 hours later at 12:01 pm.

Also, Bryan met with a neighbor that needs a home for some virgin dirt, located only a few blocks away.

Yes, another big day.

Preface

One of our stated objectives for this project is to use ‘innovative building materials’.  We are one of the first single family residential homes to use hollow core concrete panels in Northern California.  We engaged Bill Brown Construction Company to partner with us on 17509 Via Sereno because:

1. Bill Brown has extensive experience in all the areas that we need expertise (e.g., seasonal perched water tables, waterproofing, ‘green’ building design and construction, etc.).
2. Bill wants to innovate and be a leader with new building products and new construction practices.
3. Bill has a great team that can ‘do the hard stuff’ that he leads personally and, most importantly, has a passion for construction while having fun.

Preparation

We wanted to get in front of the day so our plan was to assemble at 7:15, have the crane arrive at 7:30 am and get into position, and have the first truckload of hollow core concrete panels arrive at 7:45 am so we could start working at 8:00 am as we unloaded the first panel.

Chad Sisson, Summit Cranes, and Bill Brown, Bill Brown Construction Company, preparing for the day at 7:35 am.

Korolath strips, which go between the concrete retaining walls and the hollow core concrete panels. These strips help to distribute the load evenly across the concrete retaining wall

The first truckload of hollowcore concrete panels arrived on time at 7:45 am,/

Bill Brown inspecting the first load of hollowcore concrete panels.

Chad extended the boom and confirmed the crane could reach everywhere in the site that was required. We're good to go!

The First ‘Bay’ of Panels

 Chad lifted the first hollowcore concrete panel from the truck at 8:10 am.  Bill and Bryan were on ladders so they could position the first panel at the far end of the house, in the first ‘bay’. (more…)

Hanson Structural Precast confirmed our three truckloads of hollowcore concrete panels will arrive on Tuesday morning so we can start unloading (working) at 8:00 am. 

Bill Brown and his team are ready, and the weather looks perfect.

Completing the Steel

Larson Steel finished installing our steel columns and beams today.  Of course, this is a prerequisite to putting in the hollowcore concrete panels tomorrow.

We had to ensure there was always a three inch bearing surface on top of each beam.  This required moving some Nelson studs and trimming the ends of some beams.  We confirmed that our structural engineer, Innovative Structural Engineering, had verfied the conditions in each location where the steel beams were connected to either the concrete retaining walls, other steel beams, or steel columns.  Shane Lothrop confirmed each connection was acceptable.

Require 3 Inch Bearing Surface

The following photos show the conditions where we had to ensure there was a 3 inch bearing surface on the steel beams for the hollowocore concrete panels.

Nelson studs and W6x16 beam projecting into the 3 inch bearing surface for the hollowcore concrete panels.

W6x16 flush beam projecting into the bearing surface.

This W10x12 drop beam needs to be moved so our stairs can be at least 36 inches wide.

Making the Final Changes

Both Pete Larson’s team and Bill Brown’s team worked to ensure that we were prepared to place the 50 hollowcore concrete panels tomorrow morning. (more…)

We had plenty of fun celebrating Mother’s Day!

A picnic with three other families at Jason Stephens Winery near Gilroy, California, some wine tasting, and then a quick tour of our project site at Via Sereno.

Picnic at Jason Stephens Winery

We had a great table to enjoy a picnic lunch and celebrate Mother’s Day.

Happy Mother's Day!

The beautiful palm tree lined entrance to Jason Stephens winery near Gilroy, California.

Quick Tour of Via Sereno

On the way back from the picnic, we invited everyone to come see our new steel beams.  Yes, it was a big deal for us although not everyone could embrace the vision and share the excitement as we could.

Jo-Anne explaining that she is standing in the bottom of the atrium.

Jo-Anne explains his bedroom layout to our son, Nikolas.

Isn't it interesting how the guys find different things to discuss than the girls, especially at a construction site?

The steel will be completed tomorrow and we put in the hollow core concrete panels on Tuesday morning.

We placed the steel beams and columns yesterday and needed some additional assurance that the hollow core concrete panels that are being delivered from L.A. on Monday will fit when we install them on Tuesday. 

They will fit just fine.

Sinclairs Tour the Site

Jo-Anne’s parents, John and Dode Sinclair, have been here for three weeks and are returning to Canada tomorrow.  They toured the site this morning so they can follow our blog until their next visit to California. 

Although they liked the view from the front of the property, getting to the temporary deck over the pool requires going around the house by Winchester.  We explained that, if they stayed another week, they would be able to go through the house by walking on the hollow core concrete panels.

Our steel beams are looking great. They should be covered with hollow core concrete panels on Tuesday so this will be a very different view next Saturday.

Bryan points out the features in Nik's Room to Jo-Anne's mother, Dode.

John and Dode reviewing the site from the temporary observation deck.

Seasonal Perched Water Table

You can see the effects of our ‘seasonal perched water table’ in the excavation at the back of the house.  This water has increased the complexity and dramatically increased the cost of our project.

Note the water line in the soil, indicating the seasonal perched water table.

Measuring With Only One Person

Bryan had a hard time measuring the distances between the beams without someone else to hold the end of the measuring tape.  Then, he thought of using a plumb bob to identify the beam positions on the concrete floor and then measuring the distances between those beam positions.

A good idea except the ladder had to be moved for each measurement.  This required a bit more thinking before Bryan used a heavy washer at the opposite end of the string for the plumb bob.  With this method, Bryan threw the washer over a beam and then used the plumb bob and measuring tape to identify the distance from the wall, etc.

This method was easy, fast and required only one person (and not ladder).

Bryan with the plumb bob and heavy washer so he can measure the distances between the beams by himself.

Throwing the washer over a beam to hold the plumb bob.

Measuring the distance to the edge of a beam with a plumb bob and measuring tape.

Jo-Anne Reviews the Site

Late this afternoon, Jo-Anne appeared at the site.  She had been in Boston all week and had a narrow window of time between her hair appointment and Nik’s baseball game so she came to the site. 

Jo-Anne liked the stairs that Jorge had built this week and very much appreciated not having to use the ladder. 

She came bearing gifts!

Jo-Anne walks down the exterior concrete steps for the first time, bearing gifts!

Today was a huge milestone for our project.  Our structural steel is now in place, ready for the hollow core concrete panels.

Preparing for the Day

It was a perfect blue-sky, California day to place our steel columns and beams.  Not a cloud in the sky and a faint breeze to keep everything cool and comfortable.  Our 35-ton crane, from West Coast Cranes, arrived on time with the truck carrying our steel columns and beams.

Our crane, from West Coast Cranes, arrived on site promptly this morning to get set up.

The team from Larson Steel setting the bolt heights in the pockets for the steel beams.

The truck with our steel columns and beams arrived and is waiting on Winchester Boulevard.

35 ton crane from West Coast Cranes starting to extend its boom.

Note how the five outriggers are extended to level and stabilize the crane.

Having a large crane in place on a beautiful day appeared to be a trigger for visitors.  For example, Wes Wenger (Wenger Plumbing) came by as did Doug Ferannte (Los Gatos Glass).  Both had positive comments on our project as it continues to move forward.

Setting the Steel Columns in Place

The eight steel columns were set in place first, on the bolts that Bill Brown’s team embedded in the structural concrete on March 6, 2009.  These steel columns will support the steel beams.

First steel column coming from the truck.

Our first steel column being set in place by the crane, with Hector Guerra guiding it.

The last steel column is in place and the bolts are being adjusted and tightened.

Placing the Steel Beams

We have five steel drop beams that are supported by the steel columns and foundation wall.  These drop beams support two steel flush beams.

Moving the first steel beam from the truck to the site.

Hector Guerra directing the first steel beam placement over the window well.

Our 54 ft steel beam coming from the truck on Via Sereno.

Pete Larson's team putting our longest steel beam into place.

Hector guides the steel beam over the Wine Cellar into position, taking extreme care not to touch the feature concrete wall in the Atrium.

Moving the first flush beam from Via Sereno into the site.

Flush beam being lowered into place.

Our crane operator worked well with the Pete Larson's team, ensuring that the beams were placed in position gently and safely, exactly as directed. The owner of West Coast Cranes, Lowell Tucker came to our job site for a few minutes to observe the steel placement and ensure the work was going well (it was)..

First flush beam being positioned from the Atrium to the west foundation wall.

Placing the drop beam under the Dining Room and Kitchen. Note the crane operator is somewhat 'blind' as this beam is behind the Kitchen/Garage concrete feature wall.

Hector Guerra directing Pete Larson's on-site team.

John Rider Reviews the Steel Placement

John Rider (Jrider + Design), his wife Jenny, and Joel Lemons came to the site to see the steel beams being placed.  John was the focal point on our integrated design team as he ran the ArchiCAD model that was used to export and import DWG files from our design engineers to ensure all the components would ‘fit’ in our design.

John’s offices are located only minutes away on Hamilton Avenue in Campbell, California so they came just before going for lunch today.

We reflected on John’s site visit when the structural slab was poured using the boom pump truck, and smiled.

We had a several visitors come to see the steel columns and beams today.

John Rider (left), Jenny Rider and Joel Lemons watching from the observation deck as the steel beams being placed.

Our Structural Steel is in Place

With all the structural steel in place, the crane operator retracted the outriggers and secured the boom.  Then, he left the site.  Definitely a milestone event for us! 

Securing the boom and shutting down the crane.

Visits by Our Neighbors

After Pete Larson’s team and the crane left the site, we received a couple visitors.

First, Phil Knopf and his wife, Bonnie, came to the site.  They have lived in Monte Sereno, on the other side of Winchester, for more than 30 years and have seen significant changes in our community during that time.  We know Phil through his continuing leadership with Los Gatos Little League, where both our son, Nik, and daughter, Kate, play AAA and T-ball, respectively.

Although Phil had visited our site before, it had been some time and Bonnie had not seen the plans.  They were most interested in our project so Bryan gave them a thorough tour and explained the design features and energy-saving elements.  Phil and Bonnie were the first people to walk down the exterior concrete steps into the lower level.

John McLaren, a neighbor that lives four houses away on Daves Avenue, came to the site and walked the property, noting the changes since his last visit.  He used our new exterior concrete stair and avoided the water that was soaking our feature concrete walls.  Since inception, John has followed and supported our project.  He seems particularly interested in our Wine Cellar.

Another neighbor, Kel Marchbank (Marcal Construction), was on his Harley and visited the site.  Kel was over yesterday and saw the site before the steel was placed today.  He was impressed with the progress today and is looking forward to seeing the hollow core concrete panels being placed on Tuesday.

Our neighbors, Phil and Bonnie Knopf, visiting our site.

Bonnie Knopf liked the steel beams that we placed today.

Kel Marchbank stopped by to see the progress since his review yesterday.

 Bryan was smiling from ear-to-ear as he locked the gate.  It was a huge milestone today.

We poured the stairs and the window well today.  And now we’re ready to place the structural steel tomorrow.

Pouring the Stairs and Window Well

We’ve had a number of pours to date so everyone knew the drill for today.  The concrete was delivered on time and in place quickly.  The finishing the steps and the window well is important as these locations are now completed.  This is now finished concrete.

Finished exterior stairs. We need to protect these steps for the duration of our construction project and then it will make access to the lower level much easier, faster and safer.

Bryan reviews the new, finished concrete in the window well at the front of the house. Bill Brown's team did an excellent job finishing the window well.

We’re Ready for Steel

All of the forms have been removed and Bill Brown’s team cleaned the site and swept the concrete foundation so the team from Larson Steel will have a clean and safe site to work in.

Clean site, ready for steel tomorrow.

Bryan looking at the feature concrete wall in the Atrium, which is covered by plastic to keep the concrete wet as it cures.

Concrete feature wall by Kitchen.

Garage door opening in feature concrete wall.

Kel Marchbank, from Marcal Construction, arrives to review progress at our site.

Watering the Feature Concrete Wall

 We continued to water the feature concrete walls (Dining Room, Kitchen/Garage and Atrium) as instructed by Bill Brown.  Keeping the concrete wet as it cures will help to strengthen the concrete and reduce cracks.

Bryan adjusting the valve to direct water to the feature concrete wall in the Dining Room.

The site is looking good, with the daily watering of the feature concrete walls. We're ready to place our steel columns and beams tomorrow.

 Tomorrow will be a big day for us as we place our steel columns and beams.