Jo-Anne came to our job site this morning to evaluate the colored concrete alternatives. 

On Monday, 11/16/09, we poured two samples of colored concrete – Baja Red and Harvest Gold.  Bill Brown explained that, as the concrete cures, it will lighten thus it was good for a few days to go by before evaluating the samples.

We both preferred the Harvest Gold.

(The name ‘Harvest Gold’ reminds us of the appliance colors that General Electric introduced in the late 1960s, ‘Harvest Gold’ and ‘Avacado Green.’  (We’re hoping that the Harvest Gold concrete will be more timeless than the appliances.)

Jo-Anne arrives at the job site to evaluate the colored concrete samples.

Harvest Gold with the color chart.

Baja Red ...

Jo-Anne evaluating the colored concrete - we chose the Harvest Gold.

It was another beautiful blue-sky California day today.  Our goal is to complete pouring concrete inside the house before Thanksgiving so that means we need to have the radiant heating/cooling PEX loops inside the concrete before each pour.

We need to pour concrete over the hollow core concrete panels in the living area and the garage on the main level, and then pour three inches of concrete in the lower level.  On the main floor, there will be 3 inches of concrete everywhere and 5.25 inches of concrete where we are having exposed concrete.  The other areas will have hardwood flooring in a 2.25 inch system (3/4 inch subfloor, 3/4 inch PEX layer, and 3/4 inch hardwood flooring).

Bill Brown was confident that his team wouldn’t be on the ‘critical path’ and that the radiant heating/cooling (PEX) would cause delays in meeting the Thanksgiving deadline.

The gauntlet was thrown …

Silicon Valley Mechanical Improves on Our Initial Radiant Design

Several month ago we started working with Ken Martin of Silicon Valley Mechanical to design the radiant heating and cooling, and the displacement air ventilation.  Ken is a Professional Engineer and has extensive experience with innovative projects, including David Kineda’s Z-squared building in San Jose, which David won a USGBC Northern California chapter award for (and was presented at the USGBC NorCal Gala on 10/30/09).

We had engaged Monterey Energy Group for the initial design of the radiant layout, which they did.  After meeting with Ken and reviewing the preliminary design with him, Ken identified a number of innovative improvements that could be made in a cost-effective manner that would allow for simultaneous radiant heating and cooling across zones as well as heating the swimming pool and cooling the wine cellar.

The highlights of Ken’s design changes included:

• Enabling radiant cooling by controlling humidity inside the house (to control the dew point and resulting condensation).
• Increasing the diameter of the PEX from 1/2 inch to 5/8 inch, which reduces the pressure drop in a loop.
• Placing the PEX on 9 inch centers (vs 12 inch).
• Using a loop layout so the average temperature differential between the supply and return PEX yields the same differential.

Placing Our First PEX Loops

Matt Jung from 88HVAC met Bryan at the project site and showed him how to take the PEX off the spool and lay out the PEX.  Matt has extensive experience with radiant heating and this will be his first radiant heating and cooling project.

We are tying the PEX to the #3 reinforcing steel (rebar), which is placed 18 inches on center each way.  Bill Brown cautioned us to ensure that no PEX loop should be able to ‘float’ upward as he will be doing saw cuts to control the cracking in the slab.  With the PEX loops pressurized to 100 PSI, Ken Martin believes that we should be OK.  Bill would have preferred to have the PEX under the rebar; for performance purposes, we will be placing the PEX on top of the rebar so it is closer to the surface (but safe from the saw cuts).

A perfect beautiful blue-sky California day to start laying out our PEX.

Before Matt arrived, Bryan used our shop vacuum to clean the debris from the perimeter voids around the hollow core concrete panels.

Matt working with Bryan to lay out our first PEX loops and zip tie the PEX securely to the rebar.

We put our project on hold for three months while the stairs and two bridges were designed, engineered, fabricated and installed.

Bill Brown met Bryan at the project site today and reviewed the stairs and bridges.  And tested each of them.

Discussion with Bill Brown

Bryan met with Bill for several reasons.  First, Bill wanted to see the stairs and bridges, and then he wanted to know where we are with the project and what the next steps are.  Also, Bill wanted to ensure that we were satisfied with the billings to date and answer any questions that we had.

Bryan showed Bill the various components for the stairs and bridges, and explained that the 14 posts that will be welded to the steel I-beams should be delivered next week.  Larson Steel will do the field welding and ensure the posts are solidly in place before we can pour the next (final) layer of concrete.

Bill would prefer to do one monolithic pour for the entire 5-1/4 inches of concrete on the main floor.  Also, we require 3 more inches of concrete in the lower level.  Bill recommended that we work quickly on our ‘colors’ and decide on how much tint we require in the concrete mix.  Bryan mentioned that John Minton recommended that we do a monolithic pour so we take out as much of the camber in the hollow core concrete panels.

In reviewing the elevation for the finished floor, Bill pointed out that we have now established that level with the brackets in the Bridge Hall that support the GlassWalk floor system.  Bryan noted that Larson Steel will need to remove part of the bracket at each end of the bridge so there is sufficient depth for the concrete.

Our next steps include the following:

• Receive the posts and weld the posts into place.
• Bill’s team will ensure the current forms are in the correct position and put in the remaining forms with reinforcing steel and/or wire mesh.
• We will have the radiant heating and cooling PEX installed, with supply/return lines to the various manifolds.
• Pour the main floor.
• Pour the lower level.
• Strip the forms.
• After 28 days (or so), grind and polish the concrete as required.

Bill will be working on designing the concrete mix so it will include the appropriate amount of slag that works with the sealant (Ashford Formula or equivalent), the desired aggregate size (depending on how much grinding we want in the surface), the hardness of the concrete (PSI), and the amount of water required. 

He will design a mix that considers the various objectives and will limit the risk and degree of cracking that will occur (remember, concrete cracks).

Bill Walks the Property

Being very skilled around project sites and walking across steel beams, Bill tested the bridge by walking across it and bouncing in the center.  Getting defensive, Bryan explained that there will be two layers of 3/4 inch plywood on the bridge with another 3/4 inch of hardwood flooring.  Bill smiled said that he will test the bridge when it is completed.

Regarding the exposed edges of concrete and steel I-beams, Bill recommended that we grind the exposed face of the concrete and not use any stainless steel trim.

Bill Brown testing the bridge. It passed his preliminary inspection and Bill will provide his opinion on completion.

Bill checking the vertical gap between the steel I-beam and the stair stringer to ensure the 1x2 stainless steel post will fit. He believes it will, just.

Bill Brown’s words were still ringing in Bryan’s ears. 

“The bridges, railings and stairs are critical to your project.  These are what everyone will touch and feel.  The hardware on the railings are like jewelry – don’t make a mistake.”

Stopping the On Site Work

Given that we had not designed, engineered, fabricated or installed the bridges and stairs, we had to stop our on site work.  This is not good as our move-in date will slip for every day that it takes until the bridges and stairs are installed.  We have more concrete to pour but can’t do that until the bridges and stairs are in.

And, the walls and roof can’t start until the concrete is poured.

Once the roof is on, we need to have the membrane installed on the flat roof, and the shakes on the gable roof.

Then, the rains can come.

Time is of the essence, again.

Oh, another recommendation by Bill.

“Hire someone to manage your construction.” 

Good advice.

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…)

Our feature concrete walls were completed before noon today.  This marks the end of the shotcrete; the next step is to place the steel beams.  Then, we will put the hollow core concrete panels in place.

We had an error in our design so Bryan picked up the demo hammer for a workout.  However, tonight he was able to enjoy the grand opening of the Margarido House (LEED-H Platinum certified) in Oakland.

Hosting Bill Clyne’s Visit to Our Project Site

Bill Clyne, CEO of Floor Seal Technology, was interested in our project and asked if he could visit the site (to check on Bill Brown’s work and our waterproofing).  Knowing Bill C.’s expertise with sealing, polishing and staining concrete, we said that we’d be honored to host his visit.

As background, Bill Clyne has done concrete finishing work for Bill Gates, Larry Ellison, Michael Dell and Jay Leno’s Big Dog Garage.  These people were able to select the best in the world to work on their homes.  Yes, we’re in a totally different league with our modest Eichler.

Bill C. arrived shortly after 8:00 am and took a quick tour of the site.  He liked the challenges of our project and our ambition to put 1.5 million pounds of concrete in place.  Bill C. and Bryan were in the temporary site office when Bill Brown knocked on the door and came in.  Bill C. and Bill B. have known each other for some time and are good friends.

Bill Brown (left) and Bill Clyne (right) reviewing the plans in the temporary site office.

We discussed the project and asked Bill C. regarding the water in the concrete and how long it would take to dry.  Bill C. explained that the concrete would dry at approximately 1/2 inch per week so it would be several months before the concrete would be dry.  To retain moisture, he encouraged us to put a vapor barrier between the structural slab and our finished concrete (the top three inches).

The longer that water is in contact with concrete, the harder the concrete will be and the less shrinkage will occur.  Shrinkage causes cracking, especially in weak concrete.  We don’t want any cracking so we’ll ensure the concrete stays wet as it cures and that the water content is there for as long as possible.  However, we do want to have a dry house without any moisture in it.

Bill B. and Bill C. discussing the waterproofing as they watch the preparations for the shotcrete.

Preparing to Shoot Shotcrete

Shooting shotcrete requires an air compressor and hoses to shoot the shotcrete.  Also, an independent third party inspector is required to confirm the nozzleman is qualified and observe the shooting of the shotcrete.

Dees-Hennessey's air compressor and truck.

Special inspector from HP Inspections (white hard hat on left), with a load of concrete from Graniterock and the Dees-Hennessey air compressor and operator.

Delivering Documentation to the City of Monte Sereno

Bryan delivered the first documentation from Innovative Structural Engineering to the City of Monte Sereno at 9:10 am this morning.  The Building Official, Howard Bell, asked for a letter and the reinforcing steel (rebar) schedule from ISE and the wet-signed rebar schedule from Duquette Engineering. 

Bryan’s second visit to the City of Monte Sereno was to deliver two signed copies of the ISE letter, which Howard stamped and returned one to Bryan (job site copy). 

A quick trip to Duquette Engineering in Santa Clara and then back to the City of Monte Sereno with the wet-signed sketch showing the rebar layout.

We’re good to go with the shotcrete.

Shooting Shotcrete

Shooting shotcrete is quite a process involving the full team to work together.  We had one of the most experienced teams working in perfect weather today as they shot 23 yards of shotcrete.  Graniterock delivered two 7-yard loads and a 9-yard load of 5,000 PSI shotcrete (30% slag) to our site, which was shot before noon today.

Shooting shotcrete on the feature wall in the Kitchen.

Shotcrete covering the rebar in the Wine Cellar.

Nozzleman shooting shotcrete on the back wall of the Wine Cellar.

Finishing with a steel trowel on the concrete feature wall in the Kitchen.

Finishing the 18 ft feature concrete wall in the Atrium.

Feature concrete wall in the Dining Room.

Completed retaining wall in the south Window Well.

Completed shotcrete wall in the Wine Cellar, which is under the garage.

Applying a curing agent to the shotcrete.

The completed feature wall in the Dining Room is covered with plastic to retain moisture so the concrete will cure slowly to reduce the risk of cracking.

Fixing a Design Error in the Exterior Stair Well

We made a design error in the retaining wall where the exterior steps will be poured.  Having made the design error, Bryan was to fix it.  Our on-site supervisor, Jorge Ramirez, provided instructions on how to operate the heavy duty Bosch chipping hammer.

Given the 5,000 PSI strength of the foundation retaining wall and the rebar in that wall, this was not a small task.  Bryan estimated 20 minutes to complete the demolition;  Jorge said, ‘Take 30 minutes.’

Location of the concrete retaining wall that needs to be removed (1:57 PM).

Results at 5:04 PM. Note the pieces of concrete that are still attached to the Grace Preprufe 160R.

Jorge cut the Grace Preprufe 160R, so Bryan knew where to remove the concrete to.  The interesting, and comforting, observation was the concrete stayed attached to the Preprufe even though it was in pieces.  This shows the strength of the bond between the Grace Preprufe product and the concrete.  This property is what will help to keep our foundation watertight.

Grand Opening of the Margarido House

Scott Andersen, Bill Brown, Matt Jung and Bryan toured the Margarido House on Saturday, January 10, 2009.  This was the second house in northern California to be certified Platinum under the LEED for Homes program.  The owner and builder, Mike McDonald, hosted our visit in January and invited Bryan to the grand opening.  The event was from 6:00 pm to 9:00 pm tonight.

Mike McDonald speaking at the grand opening of the LEED-H Platinum certified Margarido House.

 It was a perfect end to a very long day.