There was a gap in the winter rain storms pounding Northern California so we decided to take advantage of the window and buy (pick up) the reclaimed wooden beams that we found in Hayward.

The Plan

The beams were located in Hayward, which at the intersection of Interstate 580 and Interstate 880, and we needed to move the beams to Dave Merchant’s milling operation, which is in Bonny Doon in the heart of the Santa Cruz Mountains.  Dave owns Out of the Woods, and is supplying our Madrone flooring (we toured Dave’s Out of the Woods operation in May 2009).  Since Dave wasn’t available, he suggested that I contact Rich Carpenter, who had a truck and trailer that could handle the 25 ft long beams.

Rich agreed to meet with Bryan in Los Gatos just after 9:00 am and then they would drive up to Hayward in his truck, towing the trailer.  The expected arrival time in Hayward would be around 10:30 am or so and Kenny, who is selling the beams, would have the beams ready to load.

After loading the beams, we would then take them back to the Santa Cruz Mountains for milling.

Selecting the Beams

Leaving at 9:30 am was perfect - no traffic at all and we navigated perfectly to our destination (not one wrong turn!).  When we arrived at the site in Hayward, Kenny, who was selling the beams, graciously allowed us to go through all 25+ beams that he had and select which beams we wanted.  However, this was not an easy task as the 20+ ft long beams were on his driveway and we needed to inspect each beam from within the stack.  Fortunately, Kenny had an extremely talented forklift operator, Miquel, who could navigate the forklift safely and quickly, so we could go through the beams and load the beams that we bought.

We were able to go through the beams in two hours and selected 10 beams to buy.  The beams have some steel rods in them that must be removed, as well as some nails, and there are a couple notches in the beams.  We require 6×10 beams, which are 5-1/2 inches by 9-1/4 inches and the beams that we selected were 6×12 and 6×14 beams, we we have some room to play with.  Also, only certain faces of the beams will be exposed.

Unloading the Beams

The return trip to Los Gatos was perfect - no traffic!  We cruised along safely at a good pace.  Rich dropped Bryan off in Los Gatos so he could follow Rich to Bonny Doon.  A quick lunch in Los Gatos and we were on our way.

Dave unloaded the beams quickly and Rich was gone.

Grinding the Concrete on the Ground Floor

Back to the job site and, to our surprise (and delight!), Dave and Hunter from Pacific Decorative Concrete were there working on the main floor concrete.

A big day … way, way cool.

Kenny and the driveway that Rich will back into.

Rich 'threads the needle' and backs the 25 ft long gooseneck trailer in perfectly!

Our process was for Miquel to lift the selected beams and then Rich backs up the truck/trailer to load them.

We have our 10 beams and Rich is securing the load for our trip to Bonny Doon.

These are the remaining beams that we didn't take. Kenny will have no problem selling these beams - they are beautiful timbers!

Bryan standing in front of a huge log that Dave will be milling soon.

Dave's current milling order - this is one-inch redwood in long lengths.

Dave unloading the beams from Rich

We were all anxious to see the tight growth rings on the old-growth beams so Dave cut off a small piece.

The growth rings are very tight. Later, we counted more than 105 growth rings in the segment of the tree. It is rewarding to be able to use this reclaimed wood in our house so it can continue in a new life.

Back at the house, Dave Edwards' team continued to make good progress with the framing of the soffits in Nik's room.

The job site was very busy today.  We were framing the interior walls in the lower level, measuring the openings for the windows and sliding doors, and signing a Canadian passport application.

Providing a Capillary Break Under the Pressure Treated Bottom Plates

Moisture inside a house is bad because it creates an environment where mold can flourish.  In houses that are very ‘leaky’, the moisture problem is somewhat reduced.  On the other hand, it is exacerbated in a ‘tight’ house.  There is an excellent presentation on GreenBuildingAdvisor.com entitled, ‘Got Mold? Energy Efficiency and Moisture Management‘ that was presented by Mike Guertin and Peter Yost on December 18, 2009.  It is 63 minutes long and well worth watching.

Under our Durability Planning, our integrated project team completed a Durability Risk Evaluation Form that identified all moderate- and high-risk durability issues for the building enclosure.  Then, we developed specific measures to address those issues.  In addition, we identifed and incorprated indoor moisture control measures with our plans.

Given we have an immense amount of concrete in our house, we will have a huge potential pool of moisture in that concrete.  Water can move through concrete into wood, hence building codes require pressure-treated wood wherever wood is in direct contact with concrete.

Water, however, can move through capilliary action through wood and other materails.  Thus, having a pressure treated bottom plate that is resting on concrete will prevent the moisture in the concrete from rotting the bottom plate.  The pressure treated bottom plate may allow the moisture to migrate through it to the stud walls, which may cause mold and rot.

Having a capilliary break between the bottom plate and the concrete prevents water from gaining access to the bottom plate.  We are using a product called ‘Low-E Reflective Insulation‘, which is a reflective insulation and is made of two layers of aluminum foil with a closed cell foam in between (sometimes known as ‘foil-bubble-foil’).   Bryan met Charlie Snow at West Coast Green in San Francisco on October 12, 2009, when they first discussed this project and how Low-E Reflective Insulation would provide significant benefits to increasing the energy performance of the house.

We are using Low-E Reflective Insulation in every instance where wood touches concrete.  An additional benefit in our exterior walls will be to use the Low-E Reflective Insulation between the mud sill and the foundation.  Low-E Reflective Insulation will provide a capilliary break for moisture and provide a tight seal so air cannot go through the wood and the concrete.  This will make our house tighter and more energy efficient.  Although we will have separate termite shields in place, the Low-E Reflective Insulation will provide another defensive barrier for termites.

The Low-E Reflective Reflective Insulation comes in rolls that are 48 inches wide and 125 feet long.  Our framing team cut the Low-E Reflective Insulation into strips 5-1/2 and 3-1/2 inches wide so it could go under 2×6 and 2×4 plates.

Establishing the Window and Sliding Door Opening Dimensions

As we’re framing the lower level we are zeroing in on establishing the exact dimensions for our windows and sliding glass doors.  Annie Rouse (Murray Window and Door) and Dave Edwards (Earth Bound Homes) walked through the house and reviewed the dimensions for each window and sliding glass door.

This task required an immense amount of attention to detail.  Making an error with an aluminum frame and double pane glass will be expensive and look bad.  Also, we pulled in Francisco, who is doing the actual framing on site, on several occasions so we’re all on the same page with how the windows and sliding doors will fit.

Signing a Canadian Passport Application (Guarantor)

Our friend, Mats Menhardt, is a Canadian citizen and requires a new passport (Canadian passports are only valid for five years).  His mother, Trixi, brought his completed passport application to the job site for Bryan to review and sign.

That was easy.

Roll of Low-E Reflective Insulation (48 inches wide by 125 feet long).

Close up of the packaging.

Trimming the Low-E Insulation so it will go under the 2x6 plate. Trimming the insulation was easy and fast.

The Low-E Insulation is under the 2x6 pressure treated plate and it will provide a capilliary break and prevent moisture from moving from the concrete to the wood.

Without the capilliary break, water could move through the pressure treated bottom plate and cause mold and rot in the 2x6 studs.

Dave Edwards (left) with Annie Rouse (back) and Francisco (measuring). Trixi (right) is getting the passport application out for Bryan to sign.

Trixi, holding Mats' completed and signed Canadian passport application.

Our SIPs arrived today!  Right on schedule, as promised.  We completed pouring the concrete in the lower level yesterday and our SIPs are on site today. 

Unloading Our SIPs

The three trucks arrived on time this morning.  And, our crane was there too.  Dave Edwards and his team from Earth Bound Homes were on site to unload and start staging the SIPs. 

The SIPs are loaded on the trucks in the most efficient manner for shipping, which is not the order they will be installed/erected in.  Each panel has a unique number that correspond to the layout plans.  Insulspan labels each panel on all sides so they are easy to identify.

Although Insulspan sends laminated plastic layout plans, we used our physical model to understand where the panels went in the structure and Dave directed the panels to be stages in the reverse order of how the house will be built.  That is, the last panels used are at the bottom of the stacks.

The crane could reach to the very back of our property, just!  It was interesting to see how easy the panels could move around when sliding on other panels.  In general two people could lift and slide most of the panels, with three or four people required to lift the largest panels.

We unloaded the three trucks and staged the panels in approximatedly four hours.  Dave was pleased with how smoothly the unloading went.  His team worked quickly, efficiently and safely.

And the concrete we poured yesterday looks fabulous.

Truck #1 arrives at Via Sereno as scheduled. Way cool ...

Truck #2 in waiting on Winchester Boulevard.

And, truck #3 pulls up on Winchester. The other trucks have removed their tarps - the tarp is still on this truck.

The crane is taking the first SIPs off the first truck. Yippee!

The first load being moved onto our property.

Another load of SIPs coming in.

And, another load. We need to sort the panels and stage them in the appropriate order.

You can see the SIPs are starting to stack up on our site.

Another beautiful, blue-sky California day. Perfect for unloading SIPs!

Our SIPs are stacking up nicely.

More SIPs coming onto the site ...

View from the back of the property (on top of the SIPs).

SIPs stacked in front of our temporary site office window.

SIPs with temporary blocking in to protect the OSB flanges.

The piles are getting denser ...

SIPs at the front of the property.

The first load of SIPs that came off the first truck are sitting on the stump where our underground CUDO cistern will go. These SIPs have to be moved to a different location.

Note how each panel is numbered, which corresponds to our plans and the 3D model that we made.

We need to find a good place on our site to put the Insulspan sign.

The concrete we poured yesterday looks fantastic!

We started promptly this morning and poured 27 yards of colored concrete on the ground floor.  This is the finished floor concrete on the ground floor of our house.  We will grind it lightly and then seal and polish the concrete for our finished floor.

Measuring Key Areas and Taking Pictures

Since we will be coring holes in the finished concrete for our plumbing and shooting plates into the concrete for our interior walls, and there is xxx feet of PEX buried in the concrete, Bryan placed a measuring tape in key locations where the PEX will be close to plumbing drains and pipes, and interior walls, and then took photos.  By referencing formed walls we should be able to identify exactly where the PEX is located in the concrete. 

If we are diligent, using the measurements should help us to avoid puncturing the PEX during our construction.

PEX tubing under the shower stalls to maintain a warm surface.

Measurements to ensure the holes drilled for the drains do not damage and puncture the PEX.

PEX by door to laundry room. Note the PEX between the supply and return lines, which will be used to hold a temperature sensor.

Rebar and Anchor Bolts

The Building Official at the City of Monte Sereno noted that we needed to have #4 reinforcing steel (rebar) in several areas (not #3 rebar) and that we needed to have additional anchor bolts in two shear wall locations.  He passed the inspection so we could pour concrete today.

#4 rebar in place around the atrium.

Anchor bolts in place.

Pouring 27 Yards of Colored Concrete

Overall, the pour went very well.  Our pumping truck and team were on site and set up quickly.  The first of three trucks of concrete (9 yards in each) was on site as requested at 8:30 am and everyone went into motion.  There was no wind or rain, and it was sunny, but not hot.  A perfect day to pour concrete.

Concrete from Graniterock.

Pumper in place to deliver the concrete via a hose.

Team in place ready for concrete.

Starting to pump concrete. The hose is very, very heavy and difficult to handle.

The concrete is placed evenly over the wet hollow core concrete panels.

Having distributed the concrete evenly, it is now screed to the correct level.

Working through the living room ...

Continuing to work around the house ...

Screeding the concrete in the foyer.

We're finished pumping the colored concrete on the ground floor for today. Time to clean up, have lunch and start finishing the concrete.

Cleaning the truck and pumper.

Putzmeister TK 40 pumper.

Lunch time ...

Finishing the Concrete

Bill Brown designed a mix to minimize cracking yet include 70% slag.  The concrete took some
time to set so our steel trowel finish was delayed.  Bryan brought pizza for the finishing team and our son, Nik, and daughter, Kate, helped with the pizza.  Bill Brown suggested that Nik and Kate put their names in the concrete under the hardwood floor in Kate’s bedroom (also, he delivered a stern warning that they were not to put their names in the finished concrete elsewhere!).

It was good to pour our ground floor colored concrete today.

Starting to finish the colored concrete.

Finishing the concrete in the living room.

Close up of the pressure reading - maintaining 100 PSI. Yeah!

Anchor bolts embedded on 12 inch centers for one of our shear walls.

Finishing the concrete in the master closet. This area will be covered with hardwood flooring.

Dave Edwards, from Earth Bound Homes, dropped by to see how the pour is going. Dave will be installing our SIPs after Thanksgiving.

Continuing to finish the concrete in the living room.

Bill Brown's team removed the forms and started troweling the edges. This is finished concrete.

Finished concrete ...

Our daughter, Kate, enjoying leftover pizza while Bill Brown

Nik surveying the finishers while enjoying pizza.

Under Bill Brown's supervision, Kate starts to put her name in the concrete in her bedroom.

And Nik selects the spot for his name, too.

Continuing to finish the concrete ... it has been very slow to set.

Nik's name and today's date are now entombed in concrete.

Kate completing her name ...

Making another pass with the steel trowels as the concrete is setting very slowly.

Our PEX is now laid out on the ground floor and we’re ready to pour concrete on Thursday.

Placing PEX on the Ground Floor

Matt Jung (88HVAC) sent one of his team members to help Bryan complete laying out the PEX on the main floor and zip-tying the PEX to the reinforcing steel (rebar).  There were six loops that needed to be completed that will be connected to manifolds in two locations.  These loops will be embedded in the concrete; the other four loops on the ground floor will be under the hardwood flooring.

After the PEX is laid out and fastened to the rebar, it has to be connected and pressurized to 100 PSI.  The pressurized PEX must then be inspected and approved by the CIty of Monte Sereno prior to pouring concrete.  The PEX will remain pressurized during the pour so if the PEX is damaged and punctured, the damaged location can be identified quickly (with 100 PSI air escaping!) and then repaired.

Radiant Heating/Cooling Design Implication on PEX Layout

Ken Martin of Silicon Valley Mechancial designed the PEX layout on the ground floor for both heating and cooling.  We are using 5/8 inch PEX (from Uponor), placed 9 inches on center.  The loop layout is such that there is a consistent temperature differential between the supply and return lines.  Most radiant tubing layouts have the supply line going around the perimeter of a room and then crossing back and forth inside the perimeter before exiting the room.  This layout creates hot and cold spots.  Ken designed our layout so there is one loop that is always in parallel with the other ’side’ of it.  This layout avoids hot and cold spots in the room and results in more even heating and cooling.

Translating the loop design from the plans to the actual site was a challenge and took some thinking and time, which probably contributes to why this layout is not used very often.  We want to have a very comfortable house with even heating and cooling (no hot or cold spots) so the more complex tubing layout adds value to our project.

Verifying the PEX Locations with Our Builder and Plumber

Since the PEX will be encased in concrete and we will be drilling through the concrete and attaching wall plates to the concrete with pins, we verified the PEX locations with both our builder, Dave Edwards (Earth Bound Homes), and our plumber, Wes Wenger (Wenger Plumbing).

Dave reviewed the PEX locations and took photos at key locations.  He confirmed that the PEX was in the correct locations and will be able to advise his team regarding which locations to avoid penetrating the concrete with nails and shot pins.

Wes advised us not have the PEX going under the toilets, even if it was clear of the pipe location, as the heat from the PEX could damage (melt) the wax seal connecting the toilet to the sewer pipe.  Also, Wes verified the drain location alternatives for our showers, sinks and tubs so none of the PEX would be damaged when coring through the concrete for the drains.

Results from our test pout yesterday - Harvest Gold on the left and Baja Red on the right.

PEX in the kitchen and east side of living room. Note the orange air hose for pressurizing the PEX loops and spray bottle with soapy water for testing the connections.

Living room PEX layout. There are several locations that require more zip ties to hold the PEX down against the rebar so it is safe from being damaged by the saw cuts to control cracking.

PEX layout in Kate's bathroom. Note the additional rebar to hold the PEX down where it curves so it does not float up.

PEX in foyer that is embedded in the concrete. The supply/return lines need to go under the forms in the top left. (Baja Red on the left and Harvest Gold on the right.)

Close up showing details of the PEX in the foyer. Note how the loop goes under the hardwood at the front door and then heats/cools the concrete on each side of the hardwood floor.

Rebar layout in garage over hollow core concrete panels. The rebar over the garage is #3, 12 inches on center each way. The rebar in the living areas is 18 inches on center, each way.

Dave Edwards, Earth Bound Homes, evaluating the concrete colors in the test area.

Hold down that needs to be moved slightly as it is too close to the wall.

Our concrete contractor, Bill Brown Construction, requested that we identify the borders between where we wanted our finished concrete and hardwood floors.  Dave Edwards, from Earth Bound Homes, brought his helper and snapped chalk lines showing where the finished concrete and hardwood would be located.

Adding More Concrete is Easier than Removing Excess Concrete

As a principle, is is easier to add more concrete than it is to remove excess concrete that has set.  As well, it is easier to move floor plates around on concrete to get walls straight and plumb.  Thus, we poured concrete under the areas where the wall will be.

A key decision was where to have the seam between the finished concrete floors and the hardwood.  We decided, in all cases, this line would be in the middle of each doorway.

Snap lining in the basement.

Measuring the recessed shower area in Nik