Throughout the design phase and construction phase, we have had numerous project design and planning meetings. For example, our team worked together extensively through the building permit application process as we addressed design issues that affected the overall building design.

Shane Lothrop, our Engineer of Record for the above-ground structure, was the catalyst for holding this integrated project planning meeting at the job site.  He flew in fron Southern California this morning.

Our Integrated Team Reviews the Project

Since Shane Lothrop, of Innovative Structural Engineering, was flying in from Southern California today, we brought our full team together on site so we could identify, raise, discuss and resolve any issues prior before the roof structure is in place.

Shane Lothrop, who is our Engineer of Record for the SIPs, needed to visually verify that the connections were constructed as designed.  Importantly, Shane wanted to confirm that each of the other design professionals involved in this project were satisfied with the design so he could approve the completion of the roof structure.

Shane Lothrop, with Innovative Structural Engineering, arrives at the job site with a full set of structural plans.

Prior to our integreted project planning meeting, Shane reviewed the progress to date and confirmed all the connections were being constructed as designed. He reviewed both the bottom and top of the Hardy Frames.

Shane Lothrop (left) and Dave Edwards (right) reviewed the SIPs on site together.

Shane Lothrop (left) and Ken Martin (right) confirmed the design for the displacement air ventilation relative to the building structure.

Left to right - Perry, Shane, Dave and Francisco all review the plans to ensure the structure is built as designed.

Left to right - Steve Duquette, Randy Potter, Jon Trevor and Darrel Kelly.

John Rider (left), Darrel Kelly (center) and Perry Haviland (right).

Darrel Kelly (left) is the Green Rater assigned by Davis Energy Group to our project. Darrel took the opportunity to interview each of the design professionals that were on site today. Here, Darrel discusses the progress with Shane Lothrop, Perry Haviland, Dave Edwards and John Rider.

Shane Lothrop walked around the roof to ensure the strapping connections were all in place as designed.

Shane Lothrop (holding the structural plans) and Perry Haviland (on the ladder) reviewing the lower flat roof.

Screws through the SIPs in the roof above the Hardy Frames in Kate's Bedroom.

Building with SIPs (Structural Insulated Panels) is very different from conventional ’stick frame’ construction. We engaged Dave Edwards’ team at Earth Bound Homes to install our SIPs, which we bought from Insulspan.

Assembling the SIP Roof

Our entire roof is made of 12-1/4 inch SIPs from Insulspan. Today, Bryan watched the team from Earth Bound Homes assemble the roof over the Garage.

We used a crane to place the panels for the west side of the house on the structural framing last week. This roof area was completed and the team moved the SIPs up and onto the Garage by hand. Today, they started assembling the SIP roof over the Garage.

As with framing, you can ’see’ significant progress when assembling a structure with SIPs. It was satisfying to (finally!) start seeing dramatic progress as the roof was assembled.

Hosting Vistors

We were pleased to host Wido Menhardt’s visit today. His flight to India was delayed by several days so he was able to come to the job site today.  Now, Wido claims to be on ‘India time’.

Also, Dave Cullinane dropped by to review our progress. Dave, who lives just around the corner from us, has attended several of our open house events (e.g., our ‘Open Hole (vs. Open House) event on January 31, 2009).

Celebratikng Nik’s 11th Birthday

11 years old. How did that happen?

We updated the ‘About‘ section of our blog for Nik’s age. Time is marching by!

Today, Jo-Anne didn’t have to remind Bryan to focus on the house and get it completed.

Dave Edwards (foreground) reviewing progress on the Garage roof.

SIPs staged for the Garage roof.

Cutting a SIP to reflect some design tweaks. The team from Earth Bound Homes made some minor changes (enhancements) easily and quickly with our SIPs.

Assembling the third row of SIPs on the East side of the Garage roof.

Wido Menhardt arrives at our job site! Note the casual attiire, complete with sandals.

After receiving the shop drawings for the hollow core concrete panels from John Minton, Bryan marked the locations where we can drill through the hollow core to anchor a wooden post that will support a ridge beam. One of the posts is in the Foyer, which is above the Wine Dining (with a dropped ceiling).

No sooner did Dave Cullinane arrive at our job site than he started receiving calls. (Dave's attire is somewhat more formal than Wido's attire.)

Dave walked the property and approved of our progress to date. He wanted to know when the 'Come SIP with Us' event will be held.

Singing Happy Birthday to Nikolas, who turned 11 today.

Nik likes his new clock (can you solve the equations that tell the time?).

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Dave Merchant milled three of our 6×10 beams at his Out of the Woods operation in Bonny Doon today.  That was after Darrel Kelly (Builder’s Energy Services Inc.) stopped by the project site to see our insulation being installed around our slab.  At the end of the day, Pete Janovich (Bill Brown Construction) coordinated with Dave Edwards (Earth Bound Homes) on how, now that the existing East and West exterior walls of the original house are secured to the foundation, the two temporary steel beams can be removed.

We’re moving forward.

Darrel Kelly Verifies Our Slab Insulation

Under the LEED-H program, the Green Rater assigned to our application is Darrel Kelly.  A Green Rater has the following responsibilities within the LEED for Homes Program:

• Oversight of all verification services on a LEED for Homes registered project
• Communication link between Provider Organization and Project Team
• Verification that Project Submittal Package is complete and delivery to Provider QAD

Bryan called Darrel this morning and mentioned that it would be good for him to visit the project site as the insulation is being secured around the perimeter of the slab and could be verified today.  Darrel said he would be right over.

Darrel took the opportunity to walk around the site, noting various changes since his last site visit in January 2010.

The entire perimeter of the house is insulated with at least one layer of rigid foam (R-10). Here, on the south side of the house, there are two layers of rigid foam. This location is in the garage, just over the Wine Cellar. The sewage ejector is just to the left in this photo.

Darrel Kelly arrived and started taking photos. He verified the insulation that now covers the foundation slab.

As Darrel reviewed the project site, he took a number of photos, including a photo of our FSC lumber.

More photo verification of the FSC-certified 2x4s studs.

Carlos trims the custom flashing to fit over the foam, which is insulating the edge of the slab above grade.

Milling Three Reclaimed Douglas Fir Beams to Size in Bonny Doon

After Darrel left, Bryan went to Bonny Doon (again) and worked with Dave Merchant as he milled three 6×10 reclaimed Douglas Fir beams.  Dave has a Wood Mizer LT70 mill, with remote control, that he runs in his Out of the Woods operation.

Bryan had spent some time yesterday reviewing the reclaimed 6×12 Douglas Fir beams that we had purchased so he was working with Dave to ensure our requirements were met for these three beams.

Dave brings the three beams over to the milling location while his helper, Ben, directs him.

Dave, operating the Wood Mizer saw, prepares to mill the 6x12 beam to 9-9/16 inch tall.

Dave measures the beam to ensure it was milled as required. The other two milled beams on on the left.

Going down Empire Grade into Felton. The road goes through a second-growth Redwood forest.

Bryan stopped for a few minutes to enjoy the quiet sanctity of the second growth Redwood forest on Empire Grade.

Coordinating the Removal of the Two Temporary Steel Beams

We preserved the East and West walls of the existing house.  We did so by using 60 ft long steel beams, mounted on concrete piers.  The walls were attached to the steel beams, and secured in place at the top and bottom.  This temporary structure was designed and engineered to withstand 100 mph winds.

With the foundation completed and the insulation in place (covered by the custom zinc-plated steel flashing), we could secure the mudsill to the concrete and square up each wall.  We need to coordinate the removal of the temporary steel beams with Pete Janovich, who put them in.

Pete arrived at the job site and reviewed each of the concrete piers supporting the temporary steel beams.  Pete will have his team unbolt the temporary steel beams and move them sufficiently for Dave’s team to complete the framing.

We will have a crane on site next week to unload the long beams, including the 40 ft 6×12 wooden beam.  At that time, we will use the crane to remove the two temporary steel beams and load them on a truck.

Pete Janovich (left) and Dave Edwards (right). Note the temporary steel beam supporting the existing East wall behind them.

Pete and Dave review each temporary steel beam so Dave's team can complete the framing and continue working expeditiously.

The first SIP wall panel goes into place on the South wall facing Via Sereno. The remainder of the wall will be in place within a week.