We were extremely focused on completing the installation of the single ply membrane over our flat roofs today, as the weather forecast for Sunday continues to include a 30% chance of rain.

Also, Izzy completed the trench under the sidewalk and to the Verizon (formerly GTE) underground vault on Winchester Boulevard.

Trenching to Winchester

With our Comprehensive Trenching Plan, we are harvesting 100% of the rainfall from our roof and storing it in our underground CUDO cistern.  When the cistern is full, any additional water flows directly into the back of the storm drain on Winchester Boulevard. 

Although the 4-inch perimeter drainage system is in place, it must still be connected to the underground CUDO cistern.  Yesterday, we ordered two ‘boots’ to connect the 6-inch inlet pipe and 6-inch outlet pipes to the cistern.  We ordered this boots from BTL Liners, and they were delivered today.

Our master trencher, Izzy, dug a trench to the storm drain on Winchester Boulevard.  He dug another trench to Verizon’s underground vault, 11 ft away.  We put a 2-inch conduit into this trench and backfilled it.  This conduit will go underground to our East Mechanical room, so we can have a future connection for telephone services.  We’re hoping that, some day, we will have a fiber optic connection in this conduit.

Continuing to Install Our ‘Cool Roof’ System

The five-person team from Statewide Roofing completed the basic installation of the single ply membrane over all of our flat roofs today.  They will be back on Monday to complete the detailing and to test all of the seams.

During the day, Bryan spoke with Mandy Schwietzer a Technical Services Specialist for TPO single ply membranes with Johns Manville in Littleton, Colorado regarding some issues that our Building Official, Howard Bell, had raised.  Howard was concerned with the placement of the screws holding down the tapered insulation.  He had inspected a project on Overlook Road where the tapered insulation had curled after being installed and he didn’t want that to happen with our project.

Mandy provided technical documentation and confirmed that the multiple screws holding down our membrane will ensure the tapered foam insulation will remain flat and that the membrane will be secured to the SIPs and come apart.

Statewide Roofing had a comprehensive installation guide for the complete line of single ply membrane products from Johns Manville available on our project site.

Howard approved our installation and documented his approval on our building permit.

At the end of the working day, Bryan ensured the gate was locked and all the safety signs were in place before leaving the project site.

Installing the tapered insulation over the garage, at the front of the house.

Ready to put the membrane over the tapered insulation at the front of the house. Note the small crickets in the flat part in the center of the roof.

Using a stretcher to ensure the single ply membrane is straight on the East side of the garage.

Welding an outside corner with a hot air welder around one of the skylights on the West side of the house.

The welding must be done perfectly so the membrane will be completely watertight.

Trench going to the back of the storm drain on Winchester Boulevard. We will drill through the back of the storm drain and connect our underground CUDO cistern directly to the storm drain with a 6-inch pipe.

Izzy dug a narrow trench to the Verizon (formerly GTE) underground vault and put in 2-inch conduit. This conduit will be terminate in the East Mechanical room and may, some day, have fiber optic cable in it.

The trench to the green Verizon underground vault (left side) is backfilled and compacted, and the open trench to the storm drain is covered and the sidewalk blocked safely.

The crew from Statewide Rentals clears their remaining items on the roof so we're prepared for the rain. Currently, it doesn't look like it will rain ...

Buttoned up securely for the weekend.

Although the sky is clear, the weather forecast for the upcoming week includes a 10% chance of rain.  We know that the rains are coming and we need to be weather tight.  Today, Bryan confirmed that Statewide Roofing will arrive on Wednesday, 09/15/10, to install our tapered insulation on the flat roofs.  Then, they will install the 60 mil white single-ply roof membrane over the tapered insulation.  This system is our ‘cool roof’.

In order to place the materials on the roof, they need clear access from the street.  The supervisor, Mel, explained that they will have a generator on site for their ‘welding’ equipment that will seal/weld the seams of the white TPO membrane.

Thus, Bryan needed to move some dirt.

Jerry Ditto Drops By and Reviews Our Progress

During the day, Jerry Ditto dropped by for a quick visit.  Jerry wrote the first book on Eichlers — Eichler Homes, Design for Living and has been an advisor to our project since its inception.  Jerry walked around the house, acknowledging the progress and providing encouragement.  He commented positively on the amount of light going through to the lower level (Jerry never refers to it as a ‘basement’) and how one could see the blue, California sky.

Jerry subscribes to Dwell magazine and noted that Sam Grawe, the Editor-in-Chief, wrote in his editorial for the September 2010 issue about the Eichler that he just purchased.  Sam has an Eichler built in 1962 that was designed by Claude Oakland (our Eichler was designed by Claude Oakland and built in 1969).  Jerry believes that Sam should visit our project site in person to see how we have done our remodel and added the lower level.

‘Over the past few weeks I’ve been getting to know my new house, a nicely preserved 1962 Eichler designed by Bay Area architect Claude Oakland.’

Jerry Ditto drops by to review our progress.

Our open trenches to the East, which are still open for our water overflow bypass, irrigation manifold and conduit to Verizon

The sand needs to be moved completely and the pile of soil to the left needs to be moved. This soil is to backfill around the new concrete vault that PG&E will be installing for our underground electric service. Bryan has some work to do.

It was a grueling day today as Izzy and Bryan worked on backfilling the South trench (in front of the house).  Ryan Reyna and Nik helped for a couple hours, which was very much appreciated.

Underground Infrastructure

We have a lot going on in our trenches around the house.  The contents of the trenches are all different.  Here is a brief summary of the trench contents:

• 4-inch ABS sanitary sewer drian pipes on the West side and South sides of the house
• 4-inch ABS perimeter drain pipe that takes water from the seven (7) roof downspouts and various ground drains to the underground water cistern
• 2-inch PVC electrical conduit from the East Mechanical room to the generator pad
• 1-1/2 inch PVC electrical conduit from the East Mechanical room to the swimming pool equipment pad
• 3/4-inch PVC water pipe for fresh water to the swimming pool equipment pad 
• 1-inch PVC perimeter water pipe for irrigation water to the six irrigation manifolds
• 1-inch PVC conduit for cables to connect and control the irrigation manifolds in six locations
• 1-inch PVC conduit for proprietay cables for the natural gas powered generator
• 1-inch PVC conduit for proprietay cables to control the swimming pool and spa equipment
• 3/4-inch HDPE connecting the U-tubes in the 25 vertical concrete piers in four sections of 12 U-tubes each
• 1-1/4 inch HDPE supply and return lines connecting the two geothermal ground loops
• 2-inch HDPE supply and return lines to the swimming pool and swimming pool equipment pad
• 2-inch HDPE natural gas line to generator and swimming pool equipment pad

Until the complete ground loop system is pressurized and tested successfully, and then inspected by the City of Monte Sereno, we cannot backfill the East, North and West trenches.  Similarly, we cannot backfill teh Swimming Pool and Generator trenches until the natural gas supply connections have been inspected.

The only trench we could backfill is the trench on the South side (in front of the house).

Except for the very West side and very East side, Izzy and Bryan backfilled and compacted the soil in this trench today.  Bryan will have sore muscles tomorrow.

The open trench at the South West corner of the house. About 8 linear feet of this trench can be backfilled (it is still open).

West trench looking North. Note the 4-inch black ABS pipe stubbed for downspouts from the roof drains, the 3/4-inch HDPE connecting the U-tubes in the vertical concrete piers, the three 1-inch conduits for irrigation controls and the 1-inch PVC perimter pipe for irrigation water.

North West corner of the house, showing where the ground loops will be combined in an underground vault. Also, the conduit for the control wires (low voltage) will terminate inside the vault where they will be aggregaged and then enter the house in a single conduit.

Trench going to generator and swimming pool equipment pad. This is a full trench, with 4-inch ABS drain pipe, four 1-inch PVC conduits, 3/4 inch water line, 1-inch irrigation water line, 2-inch HDPE natural gas line and 2-inch HDPE hot water return line to swimming pool pad. The two 1-1/4 inch black HDPE pipes are the supply and return lines for the ground loops on the East side of the house.

Trench going around North West corner of pool, going to the generator pad and swimming pool equipment pad.

New short trench going to swimming pool for 2-inch HDPE suction line to carry cold water from the swimming pool to cool the house.

Izzy compacting the backfilled trench at the South East corner of the house. We compacted every six (6) inches.

Izzy continuing to compact the entire trench at the South side of the house (front).

Backfilled and compacted trench at the front of the house. Done ... for today.

Unfinished part of trench at East side of front of the house. It would have been nice to have backfilled this small section today.

Entry to house is looking much, much better now.

We want to dump ‘waste heat’ into our swimming pool so the cooling system needs to be connected with our swimming pool.  In order to do so, we need to know where to locate the water supply and return.

As well, Bryan obtained the necessary connections to mount a satellite dish on the upper flat roof.  Way cool.

Dumping Waste Heat into the Swimming Pool

When we have excess heat in the house, we want to move that heat into the swimming pool.  In order to do so, we need to have a supply of water from the pool and be able to discharge that water into the pool.  Michael Benision, of MWB Pools & Spas, has been working on reshaping our pool.

Bryan consulted with Michael regarding how to integrate the house cooling system with the swimming pool.  Michael explained that the water supply should be a dedicated suction from the main pool and the discharge should go to the pool equipment pad, where he can connect it (with a check valve) to the spa supply line.  Thus, the cold water will come from the main pool and the heated water will go to the spa.  The spa and main pool are connected.

Putting a dedicated suction into the pool will be relatively easy – the critical issue is to identify the location of that dedicated suction.  On the south wall of the pool, where the suction will be ‘hidden’ from view (we want a simple, clean look to everything), there are two lights and two discharges.  We need to identify exactly where these items are so the new suction will not conflict with the lights or the discharges.

Time for Bryan to Get into the Pool

We designed the temporary pool cover so it could be opened in sections for purposes exactly like this.  The temporary pool cover is in six sections.  Four of the sections are 8 ft wide, and two of the sections are 4 ft wide (the temporary pool cover is made with 4×8 sheets of plywood).  Paul Marcaccio and Bryan built the temporary pool cover on December 7, 2008.

Bryan worked with Izzy to jack up one of the 4 ft wide sections, which was over where the steps go into the main pool.  Within 20 minutes, the section was open and Bryan got into the pool.  He could see where the high water mark was and, in general, the pool was quite clean.  There was over 20 inches of water in the bottom on the pool.

Izzy marked where the suction line will go on the South side of the pool so he could excavate a small trench to that location.

Preparing for a Satellite Dish

Although we have cable, we want to plan for placing a satellite dish on the upper flat roof.  We talked through the requirements with our home automation consultant, Brandon Smith of Brandon Smith Audio Design in Santa Cruz, and our home automation advisor, Paul Fulton.  Both Brandon and Paul believe that the best time to put in the cable and mounting system is when the house is being built.

We are going to mount a 1-5/8 inch pipe inside of a 2 inch pipe that is connected to the top layer of OSB in our upper flat SIP roof, and that pipe will extend through the SIP to another connection in the bottom layer of OSB.  The pipe will be capped until we need it and the white membrane roof will go around this penetration.

Paul Fulton recommended that we run six (6) RG-6 cables from the home automation closet in the lower level to the pipe in the upper flat roof.  Also, we will run a grounding wire so the system can be grounded safely.

Bryan needs to get the assembly mounted and the RG-6 wires run.

The pipe assembly that will support the mast for a satellite TV antenna. Note the smaller pipe socket to the left as this will go under the SIP so the mast will be supported at the top and bottom of the SIP.

The trench at the front of the house includes the 4-inch black ABS pipe that will carry our rainwater to the underground cistern. The white PVC pipe in this photo connects to the 4-inch drain so any backwash water from a potassium water softener and/or an activated charcoal filter can be collected in our underground cistern as well.

Bryan is inside the pool, under the temporary pool deck. Izzy helped Bryan to lift one of the 4 ft wide sections of the temporary plywood deck.

The new suction that will take water from the main part of the pool will be located midway between the two lights on the South side of the pool.

View under the temporary plywood deck over the pool. Note the spa on the right, by the steps.

We were looking forward to today as there were two inspections scheduled.  PG&E was to inspect our underground electrical conduit with a ‘mandrel’ and the City of Monte Sereno was to inspect our solar mounts and the conduit going to the basement. 

We ‘failed’ the mandrel inspection and scheduled another inspection for tomorrow, Wednesday 09/08/10.  The City of Monte Sereno will allow us to proceed with our construction although we owe them some updated documentation.

Failing Our Mandrel Inspection with PG&E

For underground electric service, PG&E inspects the conduit in the ground to ensure it is placed correctly and that it has the appropriate shape.  Then, they allow you to cover the conduit with earth.  The next inspection is with a mandrel.  A mandrel is a device that is pulled through the conduit that is used to verify that there is an adequate clearance through the conduit.  If, for example, one crushed the conduit during backfill then the mandrel would get stuck.

After the mandrel inspection, one must have a 2,500 lb pull tape in the conduit so PG&E can pull their cables through quickly and easily.

The ‘Green Book’ states the following:

Applicants must ensure that conduit systems are not covered or hidden from view before the facilities are inspected visually by a PG&E field inspector. The inspector must determine if the conduit system and its installation comply with all of PG&E’s specifications (e.g., type, size, schedule, radius of bends) and installation requirements before the customer backfills the trench.

After the conduit system passes PG&E’s visual inspection, including visual verification of the conduit system’s materials and the radius of the bends, the applicant must backfill the trench and compact the soil. Then, the applicant must provide PG&E with proof that the conduit system is in compliance by successfully inserting and pulling a flexible steel mandrel through the entire conduit system.

The PG&E inspector will remain onsite to ensure that the appropriately sized, flexible-steel mandrel is inserted and pulled through the length of the conduit system without encountering blockages or obstructions.

The PG&E inspector will provide a mandrel to the applicant for him or her to use during the inspection. The applicant, however, must provide the appropriate pulling tape and follow the procedures in Subsection B, below, for using the mandrel.

Bryan was waiting patiently at the job site for the inspector to arrive this morning.   When the inspector arrived, he came onto our job site and Bryan asked, ‘Where is your mandrel?’  The inspector replied, ‘The Green Book is wrong, we don’t supply the mandrel.  You do.’

Pardon me?  The Green Book is wrong?  It is fascinating that everyone at PG&E refers to the Green Book as the authoritative manual relating to all of PG&E’s procedures for residential construction.  Several times, we have been told by PG&E personnel that we should refer to their policies as set forth in the Green Book.  Here is a link to PG&E’s web site where the ‘What Has Changed‘ (updated 04/2010).  Note subsection 3.4.1, which states:

Add a paragraph saying that the PG&E inspector should provide the mandrels for the customer to use during an inspection. The PG&E inspector will provide a mandrel to the applicant for him or her to use during the inspection. The applicant, however, must provide the appropriate pulling tape and follow the procedures in item B, for using the mandrel.

So, the authoritative reference, the Green Book, is wrong.  We’ve lost faith in PG&E.  It is most fascinating how they can ‘suck and blow’ at the same time.

After the PG&E inspector had left, Bryan called the Inspection Desk and requested a new mandrel inspection for tomorrow.  Yes, the PG&E inspector will return between 7:30 am and 2:30 pm.

Bryan went to Electrical Distributors in San Jose and bought a mandrel for a 3-inch underground service and 50 ft of 2,500 lb pulling tape.  Both of which meet PG&E’s specifications.

Back to the job site and Bryan pulled the mandrel through the conduit easily and quickly.  We’re ready for tomorrow.

Inspecting Our Solar Mounts and Conduit

The Building Official from the City of Monte Sereno showed up this afternoon.  He reviewed the plans and looked at our progress on the roof.  Akeena Solar made some changes in the field so our Building Official requires an updated set of plans to show what was built.

Bryan met with Duk Lee after the inspection and explained what we need.  Akeena will file two (2) copies of the updated plans with the City of Monte Sereno.

We’re good to go with the tapered insulation on our flat roofs.

Mandrel to go through our 3-inch conduit. Note the rope on the left and the 2,500 lb pulling tape on the right.

Rope coming out of the 400 amp panel. This rope is attached to the mandrel, which must pass through the conduit to the concrete vault by the street.

The rope coming out of the conduit where the concrete vault will be located at the street. Let's see if the mandrel goes through the conduit ...

It worked! The mandrel came through the conduit quickly and easily. We're ready for the mandrel inspection tomorrow.

Although relatively inexpensive today, we believe that water is a very important resource and we would like to be exemplary in our use of water.  Our strategy is to reduce our demand for water and then to supplement the demand for irrigation by utilizing water from our underground cistern.  We will capture 100% of the rainwater from our roof in our underground cistern.  All water pumped from below our foundation will go into our underground cistern. 

Oh, we had a nasty thorn removed from our side today when, after considerable prompting, the SAM storage unit was finally removed at 5:30 pm this evening.

Completing the Underground Connections for Our Water Catchment System

The key piece of infrastructure that we need for the water catchment system from our roof and hardscape is the connection pipes to our underground cistern.  Bryan has been focusing on the various elements that will go into our trenches for the past month and it is now coming together nicely.

Essentially, the perimeter of the entire house has a network of drains, all of which are connected and empty into our 3,677 gallon underground cistern.  Our lower flat roof, to which all of the roofs drain to, has seven (7) drains that must, ultimately, connect to our underground cistern.  In addition to these 7 roof drains, there are 12 other drains around the property that take water via the water catchment system to the underground cistern.

As of today, we have all of the drains in place around the entire property, with ‘stubs’ to to each of the surface drains (on hardscape and otherwise).  This water catchment system needs to be connected to the underground cistern next week.

Testing Our Geothermal Ground Loop

The two-person team from 88HVAC, Justin and Mike, continued to work diligently today as they tested our geothermal ground loop.  Well, to be accurate, our four geothermal ground loops.

We have 13 concrete piers on the East side of the house and 12 piers on the West side of the house.  These 20-inch in diameter concrete piers go 30 ft into the earth and are on 5 ft centers.  There are two U-tubes of 3/4-inch HDPE in each concrete pier, going the full length of each pier.

Of the 25 concrete piers, there were problems with one of the two U-tubes in two of the piers.  The problems were isolated to two specific U-tubes and, fortunately, Bryan was able to resolve one of the problems today.  The problem with the remaining U-tube may not be resolved, which leaves us with a ground loop of 2,940 ft (without the problem would be 3,000 ft).

Removing the Nasty Thorn in Our Side (i.e., the SAM Storage Unit)

At 5:30 pm, a truck arrived and picked up the offending SAM storage unit from Winchester Boulevard.

Bryan had called the company earlier today to request that the SAM storage unit be removed.  Actually, he called twice today.  On the second call, Bryan was able to refer to our blog entry from yesterday so the call center person could actually see the problem first hand.  He advised the call center agent that immovable objects require a permit to be on the public right of way (i.e., street) and the Town of Los Gatos had not issued a permit for the SAM storage unit.

It was good to see the SAM storage unit leave our neighborhood.

The drainage system behind our swimming pool, at the North end of our lot. Note the yellow natural gas line (2-inch) that supplies natural gas to our auxiliary backup generator and the pool heater.

The drain lines between the house and swimming pool.

The North West corner of the house. This is the highest point of the underground perimeter drains around the house.

The West side of the house has four roof drains as well as the 12 concrete piers for the ground loop.

Close up of the South segment of the West side of the house.

Loading the SAM storage unit onto the truck.

It was good to see the SAM storage unit being loaded on the truck. . .

On the truck ... goodbye!