We spent the day working on the electrical chases in the gable roofs.  The chases must be ‘open’ throughout their length so the electrical wiring can be completed.  Any chases that are blocked are not acceptable.

This is our last chance to verify these chases are 100% clear and electrical wires can be run unobstructed in the chases because we will be covering the wood fascia on the flat roofs and gable roofs with zinc.

While it didn’t feel like a productive day, it was an important day.

To explain, let’s go back in time …

Taking an Integrated Approach to Design

We took an integrated approach to the design of our home.  Claude Oakland was the architect that designed the house in 1969.  Subsequently, we had an entire team work on the remodel of the main floor, which followed the original design by Claude Oakland and, at the same time, the team also designed the lower level (basement), which is all new construction.

An ‘integrated approach’ required consideration of architectural design, functional design (ergonomics), structural design, energy efficiency, and the durability of materials.  As well, we included the major components of the HVAC, electrical and plumbing components in the initial, integrated design.

Once the overall, integrated design of the house (remodel and new construction) was completed, the detailed structural design was addressed, which anticipated future seismic forces.  The design and structural requirements were then used for the layout design of our SIPs (Structural Insulated Panels). 

Electrical Distribution Strategy and Design

Based on the design of the house, we arrived at an electrical distribution strategy, which the original house had as well.  The electrical distribution in the original house was over the 2×8 Redwood roof decking, which comprised the roof structure (you can see how the original electrical distribution was in a photo of the deconstruction on 09/24/08).  The electrical distribution in the remodel is in the SIPs that comprise the lower and upper flat roofs, and all of the gable roofs.

To provide as much flexibility as possible, both today and in subsequent remodels, the electrical distribution must be through chases that are intuitive and logical, and easy to understand and locate.  We decided to include these chases in the perimeter SIP roof overhangs, which are outside the thermal envelope of the structure.

Background – Design, Manufacturing and Installation of SIPs

SIPs are manufactured using shop drawings for each individual SIP.  The shop drawings are developed based on the design of the house, then the overall layout of the SIPs, and the structural requirements for the house.  We provided our SIP manufacturer, Insulspan, with the overall layout of the SIPs and the structural requirements.  Insulspan then revised the overall layout and developed detailed shop drawings for each individual SIP.  The SIPs are connected (joined) with splines. 

Within Insulspan, the manufacturing group reviewed the detailed shop drawings to ensure that the SIP layout and design, as required, could be manufacturing efficiently.  Subsequently, our structural engineer of record, Innovative Structural Engineering, signed off on Insulspan’s shop drawings and then we signed off on each individual shop drawing.  This marked the completion of the SIP design, which was then passed on to Insulspan’s manufacturing group. 

Manufacturing SIPs

Insulspan’s manufacturing group made the SIPs, and included all splines not requiring dimensional lumber.  Although Insulspan could have provided a complete ‘ready to assemble’ package with every component and spline required, Insulspan could not provide FSC-certified dimensional lumber.  Accordingly, we agreed to obtain FSC-certified dimensional lumber from our own sources through a detailed cut list and FSC-certified lumber order.

The splines that Insulspan provided included both foam splines and I-joist splines.  The foam splines were included but not connected to the SIPs that were to be joined.  The I-joist splines were installed in one of the SIPs; the adjacent SIP would then be attached as part of the on-site assembly.

Importantly, the holes for the chases were drilled in each of the splines, including both the loose foam splines and the I-joist splines that were glued in place to one of the SIPs.

Assembling Our SIPs On Site

Once the SIPs were delivered to our site, each SIP was identified and placed (stacked) near to where it would ultimately be located, in reverse order.  Essentially, the first SIP to be used was at the top of the stack and the last SIP at the bottom.  This required moving the SIPs around our (very crowded) job site.

When the SIPs were assembled on site, the SIPs were connected with the appropriate splines (either foam splines, dimensional lumber or I-joists).  The assembly team had to drill holes for chases in the dimensional lumber that connected each of the SIPs.  The foam splines and I-joists had holes for the chases pre-drilled in those connections by Insulspan’s manufacturing group.

If the SIPs were manufactured as per the design and the assembly was completed as per the design (with components manufactured correctly) then the chases would be clear and open, and located as per the plans.

Verifying the Chases Are Clear

To verify the chases were open and clear, we drilled holes in each location on the ends (rakes) of the gable roofs so we could insert a length of pipe into the 1-1/2 inch chase.  That pipe should go the entire length of the chase unobstructed.

Any obstructions must be cleared prior to installing the zinc fascia.

Simple, right?

We wish.

Where Could Errors Occur?

Reviewing the process, errors could occur in the design, manufacturing and installation of the SIPs. 

Our design was documented, with each a shop drawing for each SIP.  Design errors could occur where chases in adjacent SIPs were ‘disconnected’ and those disconnections not identified prior to manufacturing and installation.  Insulspan’s review process helped to ensure that our design was robust.

Errors could occur in manufacturing, where the chases were located in locations not specified in the shop drawings.  As well, the foam pieces, with the chases, could move or be placed upside down in the manufacturing process.  Any errors in the manufacturing process should be prevented through Insulspan’s  Quality Assurance program.  Any errors that do occur in the manufacturing process should be identified through Insulspan’s Quality Control process, prior to shipping to our job site.

Finally, errors could occur in the on-site installation.  First, the dimensional lumber splines that were not provided by Insulspan had to be ‘manufactured’ (i.e., cut to length and holes drilled for chases) on the job site.  Other errors could occur where panels were not connected correctly (using the wrong foam splines, moving or ‘flipping’ the foam splines) or where panels were not assembled plumb and square (offset).  As well, the mastic used to joint the foam splines, I-joists or dimensional lumber splines could leak/drip into the chases causing blockage.

Also, the on-site installation is the last part of the process where quality control is possible.  Any errors in the design, manufacturing and installation should be identified at this time.  Prior to putting the LVL into the gable ends (rakes) and as each panel is assembled, inspection will identify blockages in the chases.

As you can see, there are multiple parties involved in the process and multiple opportunities for errors to occur.  However, there are also areas where any errors could, and should, be identified.

Last Chance

Given this is our last chance to ensure the chases are open, we decided to invest the time and effort to drill 1-1/2 inch holes through the 2x fascia and the 1-3/4 inch LVL on the gable ends (rakes).  Also, we drilled holes through the fascia and LVL in the upper flat roof.

After drilling the holes, we started by using using 20 ft long pieces of ½-inch irrigation pipe to verify that the chases were open and clear.  Subsequently, we used larger diameter pipe.  We found problems.

In several instances, we noted that the pipe was hitting foam, indicating blockages caused by the manufacturing process.  In other instances, we noted the pipe was hitting wood, indicating problems with the installation process. 

As well, we found that after removing foam blockages that there were wood blockages.  As well, after drilling through wood blockages, we found foam blockages.

Given the problems we encountered within the sample tested, we are going to verify 100% of the chases in the overhangs where our electric distribution will be.

Using a 20 ft long 1 inch inside diameter irrigation pipe to identify where the obstructions are in the electrical chases.

Before we can put our shakes on the gable roofs, the mounts for the two arrays of solar panels on the gable roofs must be installed.

The team from REC Solar installed the 24 mounts for the solar panels today.

Installing the Mounts

Our SIP gable roofs are constructed with 12-1/4 inch SIP panels from Insulspan.  The 8 ft SIP panels are connected with I joist spines and 4x12s.  The challenge is that the solar mounts need to be 48 inches on center so we used the same mount design from the upper flat SIP roof.

The installation was fairly straight forward.  After the team from REC Solar arrived, Bryan oriented them and then provided an overview of the roof components (SIPs, splines, furring strips, Securock and sheathing).  Then Bryan showed them where the relevsant plines were and where the mounts should be located.

The REC Solar team, led by Scott Fisher, then snapped chalk lines for the bottoms of the plate and started drilling the holes for the mounts.  There were six welded brackets that were installed from the inside of the roof, and then bolted to the solar mounts.  The other 18 mounting brackets were attached to the splines and other structural components with 3/8 inch lag screws.

With the solar mounts completed, we’re ready to put the shakes on the gable roofs!

The doorway at the top of the stairs, where our Fleetwood Pacific hinged door will be located. Note the actual door is just to the left of the opening.

The Fleetwood Pacific door frame, with side lite, waiting patiently in the kitchen until it will be installed.

Six solar mounts on the North side of the North gable. These mounts will support a frame for the solar panels that will straddle the roof peak.

Corresponding six solar mounts on the South side of the North gable. Note the roof jacks that Bryan purchased last night.

Solar mounts in place, on the chalk lines, on the West side of the East gable. Note the shadow that is

It was impossible to get up to Whistler in a rental car so Paul and Bryan went to see the Olympic snowboarding at Cypress Mountain.  Unfortunately, it started raining heavily so they left.  On his way out of Vancouver, Bryan took the opportunity to visit the Insulspan manufacturing facility in Delta.  Then, he enjoyed full tour and a fantastic meal at the Wise house on Bainbridge Island.

Seeing the Olympic Women’s Snowboarding

Although it was pleasant when Paul Marcaccio and Bryan left Vancouver, it was pouring rain at their arrival at Cypress Mountain.  After watching the final four snowboarders, they decided to leave the event. 

Weather 1, Spectators 0.

Touring Insulspan’s Manufacturing Facility

After returning from Cypress Mountain, Bryan left the Westin Bayshore and drove south in the rental car.  On the way, Dave Stevenson offered him a tour of Insulspan’s manufacturing facility in Delta, BC.  The facility is adjacent to Highway 91, so it was directly on the way to the Canada-U.S. border.

Dave took Bryan through the plant and showed him how they manufacture their SIPs (structural insulated panels).  All of the manufacturing waste is recycled, which is one of the reasons why SIPs are considered ‘green’ (vs the tremendous amount of construction waste that is generated through typical on-site construction activities.

Bryan even saw the exact location where our SIPs were stored after being manufactured in October.  Bill Edwards of Insulspan took photos of our SIPs on Thursday, November 5, 2009.  Our SIPs were loaded on three trucks at the manufacturing facility on Friday, November 27, 2009 and arrived at our job site on Wednesday, December 2, 2009.

We’re looking forward to hosting our second Collaborative Informational Session where Dave Stevenson can be at our project site and show others in the Bay Area how to build with SIPs.

Touring Two Homes on Bainbridge Island

Although Bryan went to Vancouver to see the 2010 Olympics on this trip, the primary focus was to see two homes on Bainbridge Island.  How these two homes were built is an interesting story.

First, the owners of the property, the Wise family, lived in the existing house while they built their guest house.  They moved into the guest house when it was completed so they could construct the main house.  This is where it gets interesting.

Rather that demolish (bad) or deconstruct (better), they chose to move the house to another location on Bainbridge Island (best).  That sounds reasonable, right?  Except they moved the house with a boat (amazing!).

The Do It Yourself Network filmed a full segment over the month that it took to move the house to its new location on Bainbridge Island.  The segment is currently being aired several times in March 2010.  You can see it under ‘Massive Moves – Floating House‘ on the Do It Yourself Network (episode DMSM-103).

Bob and Lisa Wise took Bryan on a full tour of both homes and then everyone enjoyed a fabulous dinner.

The tour of these two homes was inspiring!

View of Vancouver, including Lion's Gate Bridge and the downtown waterfront. The weather was looking ok.

Once at Cypress Mountain, we had to go through security screening. It was easy, fast and efficient.

Watching the semi-finals of the Ladies Snowboarding at the 2010 Olympics at Cypress Mountain.

On the way down, we saw the site of the aerials.

Arriving at the Insulspan manufacturing facility in Delta, Canada.

Dave Stevenson in his office, scheduling his presentation for the second Collaborative Informational Session at our project site.

Manufacting a SIP starts with huge sheets of OSB (Oriented Strand Board).

All waste in the plant is recycled and reused. A completed SIP is on the left and the white foam cuttings are being collected.

Warehousing of completed SIPs, manufactured to the specific requirements for each job.

The SIPs for our project were stored at this location (by the yellow posts) after they were manufactured in October. The green objects are styrofoam blanks, which get 'sandwiched' between the two sheets of OSB.

Bryan, Lisa and Bob, about to start the tour (cheers!). Photo by Alison Wise.

The finish detail was exceptional. You can see the vertical grain Douglas Fir cabinets and detailed reveals.

Central vacuum sweeping location in foyer. Several friends, including the Wise family, thoroughly endorse sweeping vents that are connected to the central vacuum system.

Another sweeping location under the island in the kitchen. Note the dual dishwashers.

Bryan received a call today from Bill Edwards of Insulspan.  Bill apologized for interrupting our tool shopping on ’Black Friday’ (we bought an air compressor and a DeWalt miter saw) as he wanted to advise us that our SIPs will arrive at our job site on Wednesday morning (12/02/09) at 8:00 am.

Shipping Our SIPs

Bill explained that there will be three trucks; two truckloads full of SIPs and the third truck will have the remaining SIPs and all the hardware.  He sent the photos below to show us what to expect.

We need to ensure we have a crane ready and waiting, and that we have space to store the SIPs until we can place the SIPs on the structural framing.

Once we have the SIPs, the house should come together quickly.

Our SIPs in Delta, BC (Vancouver) loaded and ready to go on Friday, 11/27/09.

Back of the truck. Note the reference numbers on each panel.

Truck #2, with more SIPs.

Front of truck #2.

The Walters Visit Our Site

It was a great Thanksgiving dinner last night and, yes, we discussed our project several times.  Worth and Lena Walters were at the dinner with their two sons, Bjorn and Andreas.  Everyone, except Bjorn, has visited our project site and, during a lull in their Black Friday shopping, they called and said they would drop by.

Jo-Anne wanted to verify the progress so she joined us, too.

The Walters inspecting progress since their last visit.

The lower level is looking fine - we need to pour concrete!

The entire roof of our house and the front wall are made from SIPs (Structural Insulated Panels) that are manufactured in Canada by Insulspan.

Dave Stevenson called us to let us know the SIPs are ready to be shipped from their plant in Delta, British Columbia.  We need to have the main floor concrete and structural framing ready to receive the SIPs.  The manufacturing of the panels is complete, so that item is off the critical path.

Now, we need to focus on concrete.

SIPs from Insulspan

We had several alternative SIP manufacturers and chose Insulspan for a number of reasons.  The team at Insulspan included Dave Stevenson, Lorne Shepert and Nancy Yao.  It was great to be working with Canadians on our project here in California.

Today, Dave had one of his colleagues, Bill Edwards, take photos of our completed SIPs.  Each panel is numbered and will be assembled at our job site.  The SIPs have chases cut for our electrical wiring, so the wiring should go in nicely. We planned for rigid conduit to go through the SIPs that will carry the DC wires from our solar panels through to the inverters in the East Mechanical Room. 

Our engineers of record, Innovative Structural Engineering, reviewed the shop drawings for the SIPs and wet-signed two copies of those shop drawings.  We will file the shop drawings with the City of Monte Sereno.

All photo credits to Bill Edwards.

Our roof SIPs, waiting patiently in Delta, BC for shipping to California.

Each SIP is unique and numbered so it can be assembed at our job site. These are all roof panels and are 12¼ inches thick, resulting in an R47 roof.

These are the gable roof panels. Our roof will have a 12:12 pitch, resulting in a 90 degree angle at the top of the roof.

You can see the splines in these roof panels. These splines are similar to an I-beam, with a thin web between the top and bottom flanges. The thin web reduces the thermal bridging.

Here are our wall and pony wall SIPs. The front wall of our house will be made from 6½ inch SIPs as will the pony walls on our flat roof. In this stack, you can see the 45 degree angle pony walls that will support the gable roofs.

It was quite a day today:

• The forecasted rains arrived, with full force.
• Our Gov. Arnold Schwarzenegger signed and vetoed numerous bills on Sunday evening, which were announced this morning.
• The City of Monte Sereno is working on our proposed sign ordinance.
• Insulspan advised us that we need to complete the shop drawings immediately otherwise our delivery commitment will not be met.

Oh, and Jo-Anne was in Washington, D.C. for the day.

(Yes, Wendy, Bryan did mail the package to you for Elizabeth this afternoon! They said it would take ~10 days or so.)

We Can Be a Net Generator of Electricity!

This was a big, big day for the solar photovoltaic industry in California.  Gov. Schwarzenegger signed bills AB 920 and and Senate Bill 32 that will allow us to generate more electricity than we consume and get paid for that .  On January 1, 2011, Californias will be able to sell electricity to the grid, at rates to be determined.

The impact on us is that we will be able to install an additional 16 photovoltaic panels on our roof, bringing the total to 48.  At 175 watts/panel, this will be an 8.4 kW system.

We need to think through how the changes will affect our strategy.

At first blush, we are thinking that we will set everything up for 32 panels and then, on December 15, 2010, buy and install another 16 panels so we have all of our roof-top real estate in photovoltaic panels that are fully functional on January 1, 2011.  Our thinking is that the performance of panels will continue to increase and the cost of panels will drop, so we will have better panels at a lower cost by waiting.  Plus, there is no incentive to install more than 32 panels until the new laws are in effect on January 1, 2011.

 Monte Sereno’s Sign Ordinance

Brian Loventhal, City Manager for Monte Sereno, called Bryan today with an update on our proposed changes to the existing ordinance.  Brian explained that the ordinance cannot direct the ‘content’ of signs so we need to change it.  He is researching what other municipalities have done with their sign ordinances and hoping that we can leverage their efforts.

It was nice of Brian to follow up with us.

 Completing the Shop Drawings for Insulspan

This has been Bryan’s focus for quite some time now.  We need to complete our shop drawings and have Insulspan manufacture our SIPs.  Well, Insulspand called Bryan today and explained that we need to send in the marked up shop drawings otherwise the committed delivery schedule will not be met.

Bryan worked with Joel Lemons at Jrider + Design today and will complete the shop drawings tomorrow.

Our First Winter Storms Arrive and Pound Us

The first winter storms of the season arrived, according to our Davis weather station, at 3:30 am this morning and dumped 5.75 inches of rain on us by 6:00 pm.

Out site has weathered the storm, so far, in reasonably good shape.  The maximum wind speed was ~30 mph and the forecast is for that to taper off, so we’re probably going to be fine.

The rainfall flooded our basement to the level of our ‘curb’ to the exterior stairwell, where the drain goes to our sump pump.

All in all, we’re in reasonable shape until Wednesday.

Our site was a bit damp today.

This should dry out in a week. Or so.