Starting to Core-Drill

We have numerous penetrations from the ground floor to the lower level through our hollow core concrete panels.  Today, we had Penhall Company core the first 12 holes.

Also, Al and Nep completed installing the temporary lighting throughout the lower level (basement) and then they worked with Bryan to put the first layer of GAF’s Deck Armor on the South face of the South gable roof.

We’re continuing the drive to be weather tight.

Engaging Penhall Company for Our Core Drilling

We need to have a number of holes through the concrete floor from the ground floor to the lower level.  These holes are for plumbing (drains, hot and cold water, and vents), the central vacuum system, electrical, radiant heating and cooling (supply/return lines), communications wiring, and air ventilation.  There were a number of ‘structural’ penetrations for Simpson Strong Tie connections (with HTT22 hold downs), which were completed and had to be in specific locations.

Provided that there are no point loads in the vicinity, John Minton, Chief Engineer for Hanson Structural Precast, advised us that we could drill holes pretty much anywhere through the hollow core concrete panels.  On the West side of the house, we have multiple penetrations for plumbing and air vents.

The single person from Penhall Company arrived at ~11:25 am and Bryan oriented him to the project and site.  Then, he set to work with his core drill and completed 4 3-inch holes, 2 5-inch holes and 6 1-inch holes.  The first 3-inch hole was in ‘open concrete’ (not a framed wall).  After getting set up, the coring started at 11:58 am and was completed at 12:06 pm.  Eight minutes to core through 11-1/4 inches of concrete.  Including orientation, start up and shut down, the 12 holes took 4 hours.

The technician doing the coring advised Bryan that he could core at an angle, and could core any size in 1/2-inch increments, from 1 inch through to 10 inches with the equipment on his truck.  He came equipped with a vacuum to clean the cuttings.  Next time, Bryan will ensure there are garbage cans in the lower level to catch the debris from each coring.  That will make cleaning up fast and easy.

We need to put scaffolding in place for any holes we require in the wall or in the ceiling (from the lower level going up.

Measuring Our Front Door Opening

Nathan Merrill, from American Ornamental Iron, came to the job site at noon to measure the opening for the door frame that he will be designing and fabricating.  Nathan reviewed the location and discussed design alternatives to ensure the door is watertight and airtight.  He wanted to confirm the dimensions in person and discuss the finishing with Bryan.

Nathan stressed that the door will be fabricated soon and that Bryan needs to identify and order the door handle hardware.  This is on the ‘critical path’ for completing the door.

We want to have the Eichler signature door in place quickly since (1) we want to be weather tight and, importantly, (2) we want to have our traditional holiday card photo taken in front of the red door.  This is a high priority item for us.

During the discussion, Bryan suggested that the door be insulated with the SpaceLoft insulation, from Aerogel.  This material, of which we have some 598 sq. ft. is R-10.3 per inch.  The material we have is 0.4 inches thick per sheet so Nathan will design and fabricate the door so we can put three layers into the cavity.  An added benefit is that the door can be completely fabricated and then welded together with the SpaceLoft inside.  The heat from the welding will not affect the insulation performance whatsoever.

Then, the conversation turned to painting.  Nathan liked the idea of completing the door before it was powder coated.  When Nathan mentioned powder coating, Bryan asked if Nathan had used Kynar paints before.  No, he had not.  Bryan explained that the sill pans and drip caps were being painted with Kynar paints, and being completed by Top Gun Industrial Finishings in Santa Clara.

There are a couple things for both Nathan and Bryan to follow up on.

The red front door will be way cool …

Protecting the Gable Roofs

The plywood deck on our gable roofs needs to be protected for two reasons.  First, we want to be weather tight soon so the forecasted rains this weekend will not delay the installation of the shakes, once they arrive from Canada.  Thus, we need to put something over the plywood decking to keep it dry until the shakes go on.

Second, the plywood deck itself needs to be protected from the shakes.  We need to have a breathable fabric, such as a 30 lb roofing felt.  However, since we have a TPO single-ply membrane flat roof, we cannot risk the ‘leakage’ of any asphalt- or oil-based substances from contaminating the TPO.

We selected Deck Armor from GAF to use for underlay.  It is a premium product and is very lightweight and lays very flat on the plywood deck.  importantly, it is water resistant yet it still breathes.  Any moisture in the plywood decking below will escape through the ridge vent as well as go through the Deck Armor.  Thus, the shakes should have a longer life as will the plywood roof deck.

Deck Armor can be exposed to UV for up to 180 days.  It will be exposed in our location for less than 30 days.

Bryan picked up two 10-square rolls from Ford Wholesale this morning and then worked with Al and Nep and installed the Deck Armor on the South side of the South gable in 75 minutes.  It was too late to take a photo today.

Anyone driving North-bound on Winchester Boulevard will see our light-blue colored roof now.

Truck from Penhall Company arrived at ~11:30 am.

Truck from Penhall Company arrived at ~11:30 am.

Core drill set up for the first 3-inch hole.

Core drill set up for the first 3-inch hole.

Drilling in progress ... almost there.

Drilling in progress … almost there.

Done! The actual drilling took eight (8) minutes (set up and tear down time not included).

Done! The actual drilling took eight (8) minutes (set up and tear down time not included).

Nathan Merrill from American Ordamental Iron arrived on site to measure the front door opening and review the design with Bryan.

Nathan Merrill from American Ornamental Iron arrived on site to measure the front door opening and review the design with Bryan.