We completed installing our CUDO cistern by 2:30 pm today.  The pile of dirt is covered and we’re ready to celebrate the arrival of 2010!

Completing the System

We needed the material to complete wrapping the exterior of the CUDO frames and that was being shipped from Los Angeles via UPS.  Gary Jones was on site first thing in the morning, preparing the folds in the material so the last piece would fit on perfectly when delivered.

After the material arrived, Doug Allard wrapped the three CUDO frames that sit on top of the cistern (for the inlet, irrigation pump, and outlet).  These three frames, once wrapped, will sit on the other 64 frames making up the cistern.

Once Gary and Doug were finished, the system then was put together.  We sealed the joints with the prescribed tape and our Graniterock mix arrived.

We ordered a one-sack mix of controlled density fill (CDF) with a four-inch slump.  This mix goes around the perimeter of the CUDO system – between the membrane material and the earth.  Using the CDF allowed us to avoid compacting the earth with a jumping jack and reduced the amount of soil we had to remove.  We ordered 4.0 cubic yards of CDF and used the remainder on top of the CUDO cistern.

As we put the CDF in, we went around the perimeter several times, filling the void partially on each pass.  This was so the pressure would be even and not push the CUDO frames to one side without it being anchored in place.

Once the CDF was around the entire perimeter, the remainder went on the top.  Then, Jose, in the excavator, started sprinkling some soil on the top until we had a layer of approximately 6 inches.  Then, we used shovels and a vibra-plate compactor to spread the soil and compact the dirt evenly over the CUDO cistern.  Then, Jose spread more soil in six inch lifts and we continued compacting.

When we reached the top of the three CUDO frames on top of the cistern, we removed the circular covers and used caulking to put the vertical pipes that will go to the surface.  Jose spread more dirt in six-inch lifts and we continued compacting with the vibra-plate compactor.

Done!  Our underground cistern is in place.

Cleaning Up

The Kristar team left and Jose continued to clean up the site with the excavator.  The moved the remaining dirt into a neat pile so it can be used to backfill the remaining voids at the front of the house and will be easily accessible with a Bobcat.  Also, he moved the stump to the front of the yard so it can be removed.

We’re ready to celebrate the arrival of 2010 – cheers!

Gary completing the wrapping of the top of the CUDO system. These are the two layers of 4x8 CUDO frames that will hold the water that we will irrigate our landscaping with.

Gary is taping one of the three wrapped CUDO frames that sits on top of the main CUDO cistern. This frame is for the pump that will provide the water to irrigate our landscaping.

A completed CUDO frame - taped and ready to be covered.

The inlet (right) and pump (left) CUDO frames are on top of the CUDO cistern. We're ready for the controlled density fill (CDF). The CDF will fill the void between the CUDO frame and the earth.

Our 4 yards of CDF (Controlled Density Fill) arrived and Jose (right) stopped the excavator to supevise the pour.

Starting to pour the CDF around the perimeter of the wrapped CUDO frames.

Carlos Torres directed the pour while Bryan (left) and Manuel (right) ensured the CDF dropped down into the void between the CUDO and the soil.

The CDF was a one-sack mix of cement and sand, with a four-inch slump. There was no aggregate (rocks) in the CDF.

Bryan is using a piece of rebar to ensure there are no air pockets in the CDF.

We ordered enough material to cover the entire CUDO system with three inches of CDF.

CDF covers the CUDO system - now we use the original soil as backfill over the excavation to bring it to grade.

We used six-inch lifts of soil and then a vibra-plate to compact the soil.

Jose, operating the excavator, deftly distributed soil over the excavation in six-inch lifts. With a 1-3/4 yard bucket and Jose's expertise, this went quickly.

Jose had sufficient reach to distribute soil over the entire CUDO system.

After bringing the soil to the top of the three CUDO frames, we removed the covers so we could attach extensions to bring the soil to grade.

Gary uses caulking to seal the joint to the CUDO frame.

We're done! The extension on the left is where the inlet (supply) pipes will be located; the extension on the right is for the irrigation pump.

Looking South (towards Via Sereno) - the third extension is where the overflow outlets will be located that will take water in a six-inch pipe under the sidewalk to the back of the storm drain on Winchester Boulevard.

We poured the remaining concrete in the house today.  This should be the last of the concrete that we pour inside the house.  It felt good today.  Very good.

Pumping Concrete into the Lower Level

The day started early since we knew it would some time for the high-slag content concrete to set (we were using 70% slag).  We had lights in place and a ladder in the window well; we’re ready pump concrete.

The pour went quite well and, yes, the concrete was taking a while to set.

John Rider came by to see our progress to date and the concrete pour.  We have been working with John on this project since July 2008.  John always comes by for key events to see our progress.

We're ready to pump the first truck. Note the plastic to simplify the cleanup.

Starting to place the colored concrete in the lower level.

The floor under the pantry is ready for concrete.

Looking from up above as we're pouring concrete.

John Rider came by to observe the pour and see our progress.

Second truck arrives with more colored concrete.

Our PEX (for the radiant heating) is holding constant pressure at 100 psi (this is good!).

Pouring the final 'strip' in the center of the atrium, going through the Snack Area to the door

Preparing to screed the final area in the center.

The floor under the panty is completed.

As expected, the concrete was taking a long time to set.

The lights that we planned for were put to good use. The high-slag concrete (70%) takes a long time to set.

We decided that we wanted to have an integral color in our concrete, and not have it stained after being poured.  We prefer to have a homogeneous color and not a ‘mottled’ look, which staining often yields.  The concrete will then be ground lightly into the ‘cream’ and then polished to a high grit count.

After reviewing the Grace color chart, we narrowed the choices to either Harvest Gold or Baja Red.  We were looking for a color to match with the Madrone hardwood flooring and trim, and Jo-Anne wanted to see what a ‘brick’ color would be like.

Granite Rock was very accomodating to our request and agreed to send us two trucks, each with two cubic yards of colored concrete.  We planned to pour the concrete at the front of the house over the hollow core concrete panels under the Master Suite where the concrete will be covered with hardwood flooring.  This allowed us to test the mix design of the concrete and see how it would be with the two colors.  Then, we could make a decision on the color for the larger pour that is scheduled for Thursday.

The hollow core concrete panels are soaked thoroughly with water prior to pouring the concrete. This helps the 3 inch topping bond to the hollow core concrete panels.

The first truck from Graniterock arrives with 2 yards of Baja Red. We are going to 'tailgate' the pour, since it is within reach of the truck.

We want to pour concrete for our exterior stairs tomorrow so we need an inspection of our reinforcing steel (rebar) today.  It was a scramble.

Inspecting the Rebar and Surveying the Window Well and Stair Well

 We submitted the wet-signed details on the reinforcing steel (rebar) placement yesterday to the City of Monte Sereno so they can inspect the rebar today.  The Building Official advised us that we needed a survey of the window well and stair well before we could pour additional concrete in these areas.

Since the surveyors from Dunbar and Craig had surveyed the four corners of our foundation on Tuesday, they simply needed to use a tape measure to confirm the exact location of the concrete foundation walls for the window well and stair well.  Then, the sheets had to be printed, wet-signed and two copies delivered to the City of Monte Sereno.

The surveyors had been to the site and it was now past 3:00 pm.  We needed to confirm the concrete order for tomorrow and Jorge, Bill Brown Construction Company’s on-site supervisor, called Bryan to confirm that the inspection would be today.  Bryan then called the City of Monte Sereno.

‘Today?’, asked Howard Bell, the Building Official for the City of Monte Sereno.  ‘I thought you wanted the inspection tomorrow.’  Bryan responded and said we had ordered concrete for tomorrow morning and we would deliver the wet-signed sheets from a licensed surveyor showing the setbacks and our compliance with those setbacks.

Discussion ensued.

The Concrete Feature Wall Emerges

The forms have been removed, showing the back of the concrete feature wall with the forms still in the concrete for the TV niche and doors.

East Mechanical room with almost all the forms removed.

Delivering the Wet-Signed Sheets to the City of Monte Sereno

Bryan arrived at Dunbar and Craig’s offices in Santa Cruz at 3:50 pm and, after confirming the dimensions on the sheets, they were printed and wet-signed.  Bryan left Santa Cruz at 4:10 pm.

Passed Inspection

Jorge called Bryan and confirmed that the City of Monte Sereno had inspected the rebar placement in the stair well and that it was as set forth in the plans from Duquette Engineering.

The wet-signed sheets from Dunbar and Craig were delivered to the City of Monte Sereno by 4:40 pm.

Only less than 30 minutes ago Jorge had cancelled the concrete order from Graniterock Concrete and pushed it to Thursday.

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.

It was raining around the Silicon Valley but not on Via Sereno.

We were humming Albert Hammond’s song all day, hoping it wouldn’t start pouring.

Starting the Day

GraniteRock supplied our 10 truckloads of concrete today, which was 50% slag, and Dees-Hennessy performed the actual shotcrete (using their equipment and mobile air compressor).

GraniteRock truck on Via Sereno, supplying concrete mix to Dees-Hennessy's pumper reservoir.

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