The installation team from Akeena Solar arrived at the job site this morning to install the mounting system on our upper flat roof.  Also, they pulled the ‘fish’ through the conduit to the storage space below the pantry.

At the same time, the two-person team from 88HVAC continued to connect the HDPE in the concrete piers on the West side of the house while Izzy backfilled and compacted the soil over the natural gas and electric conduit.

The week ended on a very positive note.

Installing the Solar Mounts on Our Upper Flat Roof

We worked with Akeena Solar to design our solar system so it would generate as much electricity as possible.  The East/West axis of our house is positioned within 13 degrees of due East/West and, on our upper flat roof alone, we have 624 square feet available for solar panels.  These factors meet two of the four requirements under LEED-H ID 1.5 Building Orientation for Solar Design.

For our latitude, the solar photovoltaic panels should be at approximately 23 degree tilt to optimize the generation of electricity.  Although we could have designed the system to have a single plane of panels then it would have been taller.  In addition, solar photovoltaic panels require periodic cleaning to maximize the production of electricity.

Since we had some space, but not sufficient space, on the roof to include walkway space between the four arrays of panels, we ‘terraced’ the arrays.  Terracing the arrays provides space between each array (row) of panels while reducing the shading of the panels by the array in front of it.

A non-terraced set of four arrays of solar panels would be taller than a terraced set and not allow easy access for cleaning the solar photovoltaic panels.

Terracing the set of four arrays lowers the overall height but requires more area for the panels. The wider the spacing between each array lowers the height of each subsequent array (the shading angle is 23 degrees for our latitude).

With the terracing, we required a frame for each array of eight panels.  These frames must be raised off the upper flat roof by mounts and these mounts will penetrate the roof membrane.  And, the conduit going from each array to the ‘combiner box’ must penetrate the roof membrane.

Detailed design on the mounts and frame for the arrays on the upper flat roof.

Duk Lee of Akeena Solar completed the detailed design of the layout and the frames (Sheet PV-1 and Sheet PV-2).  The onsite team was given the task to build the system.  The first step in building the system was to install the mounts on the upper flat roof and run the conduit on the lower flat roof that will be under the tapered insulation. 

Of course, the electrical and structural components of the system need to be inspected by the City of Monte Sereno …

The installation team from Akeena arrived on site as scheduled this morning.  They took care to park on Winchester Boulevard so their vehicles did not use any of the precious parking space on Via Sereno.  After an orientation and brief tour of the project, they set to work laying out the solar mounts.  Later in the morning, Duk Lee arrived to verify the layout was as designed.  As well, Ben Caschera, the installation manager with Akeena Solar came to the project site to see how his team was doing.

There were some difficulties with the ‘fish tape’ going through the dedicated conduit that will carry the DC and AC from the roof to the East Mechanical room.  No problem.  The installation team used a shop vacuum to pull a nylon string attached to a small plastic ‘balloon’ through the conduit.  Within minutes, the fish tape was then in place.

At the end of the day, Don Henderson, the senior person on the installation team, called for an inspection for Monday afternoon with the City of Monte Sereno.  After ensuring the site was clean and secure, Don called it a week.

Backfilling and Compacting the Trench for Natural Gas and Electricity

Izzy completed the backfilling and compacting of our trench this afternoon.  Completing the backfilling created a significant amount of real estate at the front of the property.  Also, it made the site much safer and easier to get around.  Izzy’s next task was to put the 4 inch pipe in place around the perimeter of the house that will take 100% of the water from the roof to our underground cistern.  He got a good start on this today and will finish it by Wednesday.

Connecting the Ground Loops

Justin and Michael from 88HVAC were on site again today.  They connected two ground loops in each concrete pier on the West side of the house.  Next week they will test the ground loops in each concrete pier for adequate flow and pressure.  If that test is OK, then they will connect the concrete piers and bring the complete ground loop inside the house to the West Mechanical room.

Overall, we’re continuing to make progress.  And progress is good.

Starting to lay out where the mounts will be located on the upper flat roof. The cool night resulting in very heavy condensation on the newly Tyveked roof.

Izzy was backfilling and compacting the trench for the natural gas and underground electric conduit.

The team from Akeena Solar installs the mounts on the upper flat roof. It was a beautiful, blue-sky California day (again).

The acorn nuts can now be covered with the tapered foam insulation such that the member will not be damaged over time.

Don Henderson, from Akeena Solar, in an animated telephone conversation on our upper flat roof.

Conduit that will take the AC lines from the North gable roof to the East Mechanical room.

Don reviews progress.

The solar mounts are looking good! The tapered insulation will cover the solar mounts.

Don Henderson calls it a day. And a week. The team from Akeena Solar will be back on Monday to finish the last items and then the City of Monte Sereno will inspect the progress on Monday afternoon.

Other than the location for the new electric service box, the trench with the natural gas and electric is backfilled and compacted. The pile of dirt is much smaller now!

After taking the flag down, Bryan smiled and took one last picture of the solar mounts on the upper flat roof.

It was Los Gatos Little League Day today and we were there with Nik and Kate for the opening ceremonies (Nik is playing AAA on the Red Sox and Kate is playing Machine Pitch with the Orioles). 

After the ceremonies, Jo-Anne walked with Nik and Kate a few blocks to Starbucks to burn some energy and get some coffee.  Our neighbor, Kel Marchbank, was there and said, ‘Saw you guys in the San Jose Mercury News today.’

Way, way cool …

San Jose Mercury News, April 4, 2010

How Eichler’s ‘California Modern’ is going green
By Judy Peterson
Bay Area News Group

When real estate developer Joseph Eichler started building homes in Northern California in 1950, he targeted middle-class home buyers who appreciated the houses’ light and airy architecture that eventually became known as California Modern. With skylights and floor-to-ceiling windows that looked out onto gardens, patios and pools, the houses reflected Eichler’s vision was to “Bring the Outside In.”

Fast forward to the 1960s, when Eichler set his sights on Monte Sereno, building a 16-house subdivision on Via Sereno, off Winchester Boulevard. One of those Eichlers is being rebuilt to reflect what could well be called California Green. The new California style is sustainable, healthier homes, with many homeowners trying to achieve LEED (Leadership in Energy and Environmental Design) certification.

Homeowners Bryan and Jo-Anne Mekechuk bought their 1969 Eichler in 1997. At the time, they had no children. Now they have two, plus they needed room for visiting grandparents. So, it was time to remodel.

At first, the couple considered adding a second story.

“A second floor on an Eichler is not appropriate,” Mekechuk says.

Instead, they took the house apart board by board and dug a basement. Even so, Mekechuk says the home will remain true to Eichler’s vision.

“We kept all the design,” Mekechuk said. “The footprint of the house is identical. For example, the garage door is in the same place.”

Well, almost identical. Besides the basement, 18 square feet was added and three windows were moved. But two windows at the front of the home are identical and Eichler’s trademark atrium will be rebuilt.

Mekechuk is reusing 100 percent of the original home’s redwood boarding, while adding structural insulated panels-styrofoam insulation sandwiched between plywood. Mekechuk gets LEED points for that. The LEED rating system gives homeowners points that, when added up, can determine if a house is LEED certified or if it is certified as silver, gold or platinum. Mekechuk is shooting for platinum.

The Mekechuks also get points for holding educational open houses.

But it is the guts of the house itself that will determine if they reach their platinum goal. That’s why a cistern was dug to capture rainwater that will irrigate drought-tolerant plants. Polished concrete floors are a key element as well.

“It’s easy to keep concrete clean, plus it doesn’t trap dust and dander,” Bryan Mekechuk says. The concrete floors are composed of 70 percent slag. “Slag is a byproduct of steel production. Slag usually goes to the landfill,” he adds.

The house will be heated and cooled by a geothermal system.

“Geothermal takes warm water out of the ground and uses it to heat the house through tubing in the concrete floors,” Mekechuk says. “Cooling is the reverse of that.”

Mekechuk also plans to put 48 solar panels on the roof.

“Monte Sereno is really pulling out all the stops to encourage this kind of project,” Mayor Don Perry said at a recent open house. “We’ve waived all permit fees for solar panels. We’re really proud of this project.”

Mekechuk expects his new “Eichler Green” to be completed by late October.

© San Jose Mercury News.

We completed several tasks on our critical path to completing our SIP roof today.  An important task was to have all of the beams on site so they could be graded.  Having our beams is critical so the structural framing can be completed on the ground floor so we can move the SIPs onto the roof with the crane on Wednesday.

Picking Up Our Reclaimed Beams After Milling in Watsonville

Dave Merchant, from Out of the Woods, loaded the three beams that we milled to size on Tuesday at his site in Bonny Doon.  Dave met Bryan in Watsonville at Jackel Enterprises, where we loaded the remainder of the beams that were being milled.  From there, Bryan followed Dave up Highway #1 and over the hill to our project site.  There, our framing crew unloaded the beams by hand and staged them for grading.

Charlie Jourdain, from Redwood Inspection Service in Pleasant Hill, arrived on our site as planned and the beams were ready for him.  Charlie examined and graded each beam, then stamped the end of each beam.  He will be sending us a certificate stating the grade of each beam.  Note that Redwood Inspection Service is a division of California Redwood Association, of which Charlie is the President.

Loading our recently milled reclaimed Douglas Fir beams in Watsonville. The beams on the truck were milled by Dave Merchant in Bonny Doon.

Bryan followed Dave's truck back from Watsonville. Dave is going up Winchester Boulevard with our reclaimed beams.

Dave backed the trailer into our site so it could be unloaded quickly and easily.

Charlie Jourdain, President of California Redwood Association, came to our job site and graded our reclaimed beams. Charlie is measuring the grain of the wood as the grain runs diagonally in this beam.

Charlie measured and graded all of our beams on site, which were just delivered a few hours ago.

Making Insulated Headers

On the West side of our house we have two bathrooms.  The beams that support the SIP roof at the front and back of the house extend through the building.  However, we have two bathrooms on the West side and, even with exhaust fans, these bathrooms will have a high moisture content.

To provide greater protection from condensation, our durability plan requires insulated headers to keep keep the surfaces of the exposed beams warmer and prevent condensation from occuring. 

From two of the reclaimed Douglas Fir beams, we had Jackel Enterprises cut two 1-3/4 inch wide planks.  Using these planks, we sandwiched 2 inches of rigid R-10 insulation.  Thus, we end up with an insulated header that is 5-1/2 inches wide and over 19 ft long.  This insulated header will be over the windows in the two bathrooms.

Similarly, we require a small insulated header on the East side of the house, above the exterior Kitchen door.

Francisco makes the insulated headers by sandwiching 2 inches of rigid insulation between two planks, cut from our reclaimed Douglas Fir beams.

Completed insulated header. The two pieces of reclaimed Douglas Fir are held together by a number of 4-1/2 inch galvanized Simpson Strong Tie SDS screws, countersunk into the planks.

Moving the Temporary Steel Beams

The temporary steel beams supporting the existing East and West walls of our house were moved clear of the structure today.  Several inches of the concrete haunches were removed so the existing walls are now free and clear, and are entirely supported by the house once again.

We’re ready to remove the temporary steel beams from the site on Wednesday, February 24.

Reducing Construction Waste

Renovation and construction projects can generate a tremendous amount of waste that goes to landfill sites.  According to the LEED for Homes Reference Guide, ‘Construction and demolition wastes constitute about 40% of the total solid waste stream in the United States.’  For our project, we are targeting to create as little construction waste as possible.  When our Green Rater, Darrel Kelly, came to our project site on Tuesday, February 16, he was surprised, and delighted, to see how little waste we were generating as we were using three 35 gallon garbage bins to hold our framing debris.

Earth Bound Homes delivered a trailer to our job site today that will be used for all the framing debris.  All the framing waste on our job site was dumped into the trailer as it will be taken for recycling.  We will obtain tags on the debris removed with the trailer.

This is the trailer from Earth Bound Homes, which contains all of our framing debris to date. Note that a number of the pieces in trailer are reclaimed wood, which would otherwise be landfill. This debris will be taken for recycling, not landfill. Reduce, reuse and recycle (redirect).

Overview and Inspection of Progress this Week

Given the days are longer now, Jo-Anne was able to drop by the job site at the end of the day today to inspect our progress. 

Our first major shear wall is in place in Kate’s bedroom (formerly the Master Bedroom).  Having the shear wall in place prior to Jo-Anne’s inspection showed significant progress. 

In line with that shear wall is another shear wall adjacent to the Atrium.  Scott Andersen, who did the conceptual design of the remodel, specified during his most recent job site progress review that we include recessed art niches in the wall behind the glass bridge to the Master Suite.  Three recessed art niches were framed in today and the plywood will be nailed in place next week.

Jo-Anne walked the property and was smiling as she was pleased with our progress this week.

Completed SIP walls on either side of our doorway at the front of the house.

Same view of the foyer, taken on September 29, 2008 when the roof was being deconstructed. Note the diagonal brace on the temporary site fence through the door - it is the same diagonal brace in the photo above. Way cool.

Three art niches that are framed in the shear wall behind the glass bridge facing the Atrium.

Example of recessed art niches (not in a contemporary style house).

Example of recessed art niches on a large exposed wall.

Plywood 2x6 shear wall between the Living Room and Kate's Bedroom.

Jo-Anne, standing in Kate's Bedroom, smiles as she walks the property inspecting our progress this week.

Our flag is flying and our Insulspan sign is posted. The site is buttoned up, ready for the rain that is forecasted through the weekend.

We were surprised to see FSC lumber at The Home Depot today.  While many say ‘building green’ is costly, due to the higher cost of ‘green’ materials (e.g., FSC lumber), it is comforting to see FSC materials at a low-cost supplier, such as The Home Depot.

FSC Certification

The Forest Stewardship Council (FSC) established set of criteria that are used to review and certify wood products that meet their standards.  The following is from the ‘About FSC’ page on the Forest Stewardship Council’s web site:

FSC is an independent, non-governmental, not for profit organization established to promote the responsible management of the world’s forests. FSC is a certification system that provides internationally recognized standard-setting, trademark assurance and accreditation services to companies, organizations, and communities interested in responsible forestry.

The FSC label provides a credible link between responsible production and consumption of forest products, enabling consumers and businesses to make purchasing decisions that benefit people and the environment as well as providing ongoing business value.

FSC is represented in more than 50 countries around the world.

FSC is an international association of members consisting of a diverse group of representatives from environmental and social groups, the timber trade and the forestry profession, indigenous people’s organizations, responsible corporations, community forestry groups and forest product certification organizations from around the world. FSC has a unique governance structure that is built upon the principles of participation, democracy and equity.

Here is a link to a consumer brochure published by the FSC.

Why FSC?

If we were not participating in the LEED for Homes program (LEED-H), we probably would not understand the importance and value of cerification of wood products by the FSC.  And we most certainly wouldn’t pay a premium price for their certification.

As we went through the LEED-H criteria, we noted that using FSC certified wood is only a prerequisite for tropical wood, and not for other wood products (e.g., framing lumber).  MR 2.1 is the prerequisite that states:

2.1 FSC Certified Tropical Wood: Meet the following two requirements, as applicable:

a) Provide all wood product suppliers with a notice containing all of the following elements:

i.) a statement that the builder’s preference is to purchase products containing tropical wood only if it is FSC-certified;

ii.) request for the country of manufacture of each product supplied; and

iii.) request for a list of FSC-certified tropical wood products the vendor can supply.

b) If tropical wood is intentionally used (i.e., specified in purchasing documents) use only FSC-certified wood products. Reused or reclaimed products are exempt.

Note: A species of wood is considered tropical for the purposes of this prerequisite if it is grown in a country that lies between the Tropics of Cancer and Capricorn.

LEED-H Points for Environmentally Preferable Products

Under the LEED-H program, we can receive points for using ‘environmentally preferable products’ so this is where we are incented to use FSC certified lumber in our framing.  There are 8 points available, with up to 4 additional points for exemplary performance.  There are 0.5 points available for meeting the criteria set forth in Table 1 under MR 2.2.

MR 2.2 states:

2.2 Environmentally Preferable Products (0.5 point each, maximum 8 points).  Use building component materials that meet one or more of the criteria below. Except as noted in Table 1, a material must make up 90% of the component, by weight or volume. A single component that meets each criterion (i.e., environmentally preferable, low emissions, and local sourcing) can earn points for each.

a) Environmentally preferable products (0.5 point per component). Use products that meet the specifications in Table 1.

Note: Recycled content products must contain a minimum of 25% postconsumer recycled content, except as noted in Table 1. Postindustrial (preconsumer) recycled content must be counted at half the rate of postconsumer content.

AND/OR

b) Low emissions (0.5 point per component). Use products that meet the emissions specifications in Table 1.

AND/OR

c) Local production (0.5 point per component). Use products that were extracted, processed, and manufactured within 500 miles of the home.

So, drilling into Table 1, we find the relevant ’components’ include exterior wall framing/wall structure, flooring, floor framing, interior wall framing, trim, roof framing, and roof, floor and wall sheathing.

We will receive 0.5 points by using recycled, FSC-certified, or reclaimed material in in each of these components of our home.

FSC-certified lumber at The Home Depot.

FSC certification label.

Priced competitively at The Home Depot.

We’re trying to get our CUDO cistern installed next week so that item is completed and stroked off ‘the list’ (an achievement for 2009).  This will require excavating so we need to confirm where the underground utilities are located.  Call before you dig …

Harvesting Rainwater at 17509 Via Sereno for Irrigation

Our plan is to harvest 100% of the rainwater from our roof and just under 100% of the rainwater from our hardscape for irrigation (the water from the driveway will flow into a small swale).  The water will be stored in an underground CUDO cistern (with capacity of 3,677 gallons).  We will have a pump in the cistern that will be connected to our irrigation system so we will avoid using potable water for irrigation.

LEED Points

Our design will provide LEED points in a number of areas.  Under WE 1.1 Water Reuse, we will get 3 (of 4) points for harvesting rainwater for external use.  We cannot use water inside the house so we are giving up one point here.  Since our system is designed to harvest rainwater from 100% of the roof area, we are eligible for an additional point for Exemplary Performance.

Also, we will receive points under SS 4 Surface Water Management under Sustainable Sites.  Specifically, we will receive 3 of 4 points for having over 90% of the hardscape surface water going to a cistern (SS 4.1 Permeable Lot), 2 of 2 points for Management of Runoff from Roof (SS 4.4) since we installed permanent stormwater controls to manage runoff from the home and we had a professional engineer design our lot to manage runoff from our home on site.  

Consequently, our complete underground CUDO cistern system will result in 9 LEED points (of 136 possible points).

Underground Requirements

Once the underground CUDO cistern is full, any additional water will flow to the back of the storm drain in an underground 6-inch pipe.  This design was approved by the Town of Los Gatos (they own the storm drain) and the City of Monte Sereno.  Yes, we will require easements fro  m each municipality.

The 6-inch underground pipe needs clear access to the back of the storm drain and it will go under the sidewalk.  This is where we need clear access from other utilities.  All of the services on Via Sereno are underground so we need to ensure the cable TV (Comcast), telephone (Verizon), water and sewer (San Jose Water Company), electricity and natural gas (PG&E) and street lighting and not located where we will be digging.

So … we marked our excavation locations with white paint and called USA (Underground Service Alert) so they could visit the site and identify where all of the underground services are located.

White paint showing where we plan to excavate from the underground CUDO cistern, under the sidewalk, to the back of the storm drain.

We’re Clear to Dig!

We received notification that all of the service providers (Verizon, PG&E, etc.) had been to our site and marked the location of their underground services.  There are no underground services in the path from our underground CUDO cistern to the back of the storm drain – we’re clear to dig!

Our biggest concern was that there could be some underground utilities in the dirt strip between the curb and sidewalk, which would increase the depth of the excavation for the drain and require us to dig by hand.

The markings are on Winchester Boulevard so there is nothing in the dirt strip at the left. We're good!

Markings on the curb and sidewalk. Note the very faint marking by the light standard showing the power source is going toward the sidewalk and not into the path of where we need to dig.

We are planning to increase the structural strength of our building so it will meet the upcoming changes to the seismic building code requirements.  The U.S. Geological Survey is updating their maps and those changes will take effect with the update in the building codes in California. 

Perry Haviland, FAIA, is on the Structural Design/Lateral Forces Committee, which is part of the Code Change Committee that will be recommending changes to the California Building Standards Commission. Perry is currently reviewing our design, including the structural elements.

If we were planning to build this house and then sell it, we would simply meet the minimum code requirements and be done.  However, since we are planning to live in the house for the next 15 years and we believe that a major seismic event will occur during that time, we will do our best to strengthen the various components of the structure without retrofitting any of the materials that have already been completed (e.g., our concrete and SIPs).  Increasing the structural strength is part of our Durability Risk Assessment. 

Under the LEED-H requirements, the Durability Planning prerequisite (ID 2.1) requires that our project team address durability explicitly in the home design by assessing durability risk factors and identifying and incorporating specific measures into the home’s design to address each factor. Our team completed the Durability Risk Assessment and, with us living less than five miles from the San Andreas fault line.  We need to address the high risk of seismic activity.

We requested our structural engineer of record, Innovative Structural Engineering, to review and approve our proposed changes to increase the structural strength of our building.  As part of that review, Shane Lothrop needs to know the spacing of the anchor bolts that are embedded in the top of the concrete wall between the atrium and the garage.

A digital camera and measuring tape tell the story nicely.

These anchor bolts are embedded in the concrete.

First two anchor bolts.

Second two anchor bolts.

The anchor bolts are offset from each other in a staggered manner.

Other offset.

Another view of the anchor bolts.