It was a full day today.

Al continued working on the roof, trying to stay in front of the forecasted rains for tomorrow (100% probability).  Bryan met with the City of Monte Sereno to review our preliminary lighting control plans, John Rider dropped by to see how the project is developing, Bryan and John met with Nathan Merrill to review the progress on our red front door, and Shane Lothrop provided instructions on how we could make an opening in one of our shear walls.

And our daughter, Kate, was on the winning team for her first AA baseball game with Los Gatos Little League (Kate plays hardball).

Reviewing Progress on Our Red Front Door

During John Rider’s quick walk-through of our project, Nathan Merrill called Bryan and asked if he could move the scheduled time of 2:00 pm forward to noon for Bryan to to review the progress Nathan was making on our red front door.  With John having to go back to his office, it was perfect!  John followed Bryan in his truck to Nathan’s shop on Dell Avenue.

John Rider has worked on our project since July 2008.  John is a LEED-accredited professional and is now accredited under the LEED for Homes program.  John dropped by to say that he wants to complete the preliminary rating review on our project and finalize the plans so we can proceed.  Darrel Kelly, our Green-rater under the LEED for homes program has been encouraging us to schedule another integrated project meeting to complete our preliminary rating.  John is with Jrider + Design.

Bryan introduced John to Nathan Merrill, of American Ornamental Iron and then Nathan took us into his shop.  Nathan had our door hanging from his shop forklift, so he could work on it. 

Nathan explained that he is planning to have the door powder coated and asked Bryan to sign off on the colors for the frame and the door.  Nathan has the original red front door in his shop and will take it to the powder coating firm so they can match the color.

John was impressed with the Valli & Valli hardware and Nathan showed John the details where he will not only be meeting the specifications and finish by Valli & Valli but exceeding them.  For example, Nathan is ensuring that all the edges of the door have the same rounding radius (.0625 inch) and that the stainless steel recessed machine bolts are brushed as per the Valli & Valli finish.  Detail is key …

Making an Opening in Our Shear Wall

The recent earthquake and resulting tsumani in Japan shocked us and underscored the importance of exceeding the local seismic requirements.  Since our objective is to live in this house for the next 15 years, we don’t want to meet code requirements – we must exceed those requirements.  We believe strongly that the San Francisco Bay Area will experience a 7.5 or greater earthquake in the next 15 years.

For our lighting control panels, Bryan reviewed locations in the house and then met with our Building Official at the City of Monte Sereno, Howard Bell, this morning to discuss our proposed locations.  Howard reviewed the alternatives with Bryan and recommended that we make an opening in our shear wall in the upper laundry room to do so.  If we go with that location then Howard requires us to review the opening with our Structural Engineer of Record, Shane Lothrop of Innovative Structural Engineering.

Shane reviewed the proposed location and then sent Bryan written instructions on where and how to make the opening.  Those instructions included requirements on the opening so it will maintain the structural integrity of the shear wall.

Nathan Merrill (left) and John Rider discuss our red front door (hanging from the forks of the forklift).

The door, including sidelights. Nathan is fabricating the components around the door. Note that the piece at the bottom of the door is a brace that will be removed before it is installed.

The door opens in, using four Soss hinges (invisible hinges). Nathan explained that the door will need some cycles to get the hinges working smoothly (the door weighs 246 lbs).

Close up of the Valli & Valli hardware exterior hardware.

Close up of the electrified mortise lockset. The Valli & Valli logo on the inside door handle can be seen, just barely. Nathan's logo and the serial number will be on the top of the door.

Jig for making the wine racks. There is a left and right jig as we will require 76 of the individual supports to be manufactured.

The other half of the jig.

The first of some 24 vertical pieces in each of the three wine racks (left, center and right).

Alan holding the first component of the wine rack in the wine cellar. Note the clearance at the top of the rack, by the ceiling where the radiant cooling will be installed.

Shear wall by Upper Laundry Room. The framed area to the left is for one of three art niches; the stud bay to the right is where we would like the opening in the shear wall.

Shear wall from Upper Laundry Room, showing where we would like the opening for the lighting control system.

The electric cables for the lights in the ceiling will be run up these posts. We will drill through each post to bring the electricity to the exterior fixtures that will light the underside of the upper flat roof.

In order to bring the electric circuits from the West side to the East side, we will have to drill eight holes through this beam.

Our daughter, Kate Mekechuk, in her first AA game catching in the second inning. The Manager and coaching staff are by the fence, with a photographer behind them.

Darrel Kelly, John Rider and Joel Lemons arrived at our project site promptly at 11:45 am this morning to verify that the sun was now just starting to enter the house.  Bryan was there exactly at that time as he was returning from a site visit to an ultra-green residential project up the pennisula.

Bryan ordered the remaining roofing materials from Ford Wholesale, and picked up sufficient materials to get started until the bulk of the materials are delivered to the project site tomorrow (Friday) afternoon.

Visiting An ‘Ultra-Green Project’

Bryan was fortunate to visit another project up the pennisula that is being completed.  This project is very ‘green’ and has many similar construction components as our project, albeit on a larger scale.  We are particularly interested in the finishing materials being used in this project and the mechanical systems layout.

One of the challenges with sustainable construction is identifying and procuring materials and products that are produced locally in a sustainable manner that do not contain harmful compounds.  With our project, we need to specify the finishing materials and products that we require.  For example, we need to prime and finish wood surfaces throughout the house.  Also, we need fixtures and other products.

The surface area of the finished surfaces will be significant, so any off-gassing of volotile organic compounds (VOCs) is not acceptable.  Identifying and procuring zero VOC adhesives, primers and finishes is important for maintaining high indoor environmental air quality.  Essentially, we want to prevent pollutants from entering our home by not using products that contaminate the air inside our house.

Finding such products is difficult as the manufacturers of many products and materials bury the contents of their products in the MSDS (material safety data sheets) and it is time-consuming to research and identify acceptable products.  And, then one has to procure those products locally.

it is much easier and faster to visit a project where robust research has been conducted already to identify and procure acceptable materials, including adhesives, primers and finishes.  Bryan was fortunate to leverage such research on another project up the pennisula.

While at that project, Bryan reviewed the layout of the mechanical rooms.  The site he visited has a ground source heat pump using geothermal heat exchange and a mechanical system that uses multiple heat recovery ventilators.  The clothes dryers have booster fans and there is a whole-house water filtration system.  All components that we require for our home.

The mechanical rooms were well-lit with waterproof fluorescent light fixtures.  The layout of the room was simple and all pipes were labelled clearly.  Interestingly, the ground loop had a filter system to ensure the water flowing through the system was clean and had no particles in it.

The ceiling was constructed such that sound (vibrations) would be isolated to the mechanical room and not transmitted to the occupied areas above.  We need to consider sound deadening our West Mechanical room as our daughter’s bedroom is above the West Mechanical room.

Verifying the Effectiveness of Our Solar Design

The autumnal equinox occurred yesterday and our Green Rater, Darrel Kelly, came to our site at noon today to verify how much direct sunlight was entering our house through the windows.  John Rider and Joel Lemons, both from Jrider+Design, joined us to review the construction progress to date.  John did the original sun studies, using ArchiCAD.

Although Darrel, John and Joel subscribe to our construction blog and receive updates via e-mail, Bryan provided a brief overview of the status and project schedule.  To understand if the timeline was acceptable, Darrel simply asked, ‘Will you still be married at the move-in date?’ 

The group went into the lower level and noted that direct sunlight was entering the building through the sliding glass doors on the East side and the casement windows on the South side.  Bryan explained that we require solar gain in these locations because the earth is colder than the indoor desired temperature and, consequently, there is a heating load.  Importantly, the direct sunlight makes the lower level much more pleasant and immensely more habitable.  As the sun gets lower in the sky, the amount of direct sunlight entering the house in the lower level will continue to increase until the winter solstice.

Joel noted that the group should verify the amount of direct sunlight entering the house on the winter solstice.  Everyone agreed.

The next stop was the roof, to review the construction details for the top layers of the gable roof.  Bryan described the components and dimensions of the remaining layers of the gable roof (e.g., Cor-A-Vent, aluminum flashing, 1×3 furring strips, SecurRock, etc.).  Everyone agreed that the design and materials would result in a robust and enduring roof, that would be easy to maintain and have a long life.

Walking on the roof to the front of the house, everyone observed the crickets and how the flat roof had a slight pitch in all locations that will direct water to the drains and eliminate ponding.  Also, the brightness was observed and Joel commented on how this roof reduces the ‘heat island effect’ that is a problem in most urban areas.

Standing in the overhang of the gable roof in the Kitchen (over the garage), Darrel verified that a sliver of direct sunlight is now starting to enter the Kitchen.  As the sun gets lower in the sky, more direct sunlight will land on the concrete floor in the Kitchen and create some solar heat gain.  This is desired as the degree days increase after the automnal equinox.

Having verified everything at the site, the meeting moved to another location to discuss the subsequent construction activities and material selections.  Bryan showed the group the sample of ducting manufactured by Zehnder that we are evaluating and considering for our house.  The benefit of the ducting is that it is, like a plumbing system, very ‘tight’ and will allow us to use a heat recovery ventilator while utilizing displacement air ventilation.  Ken Martin, from Silicon Valley Mechanical, is working on the design of the system.

Picking Up Securock from Ford Wholesale

To ensure the team from Earth Bound Homes can start first thing tomorrow morning, Bryan picked up 22 sheets of 1/4-inch Securock and three rolls of 20-inch aluminum flashing.

We’re ready to start the gable roofs tomorrow.

The filter (green) and pump (red) for the geothermal heat exchange system. Note the unstrut materials used.

Mythic multi-purpose primer in a 5 gallon container.

Rubio Monocoat Oil Plus finish, with 0% VOCs.

Joel Lemons (left), Darrel Kelly (taking photos) and John Rider (right) reviewing construction to date.

The supply and return lines on the West side of the house split into two ground loops, containing six piers in each loop.

John Rider reviews the work to date on the roof.

Roof access will be much different when the gable windows are installed.

Everyone liked the sidewalk repair on Winchester Boulevard. The pedestrians were happy, too.

Picking up Securock from Ford Wholesale in San Jose.

Ute called me yesterday and mentioned that she saw our construction blog and was most interested in seeing our cistern.  She is completing a project in Los Altos and would like to include a rainwater catchment system, including a cistern.

Ute explained that she is a client of John Rider.

Hosting the Site Visit

Ute arrived at our site and Bryan took her on a full tour.

After the tour, Ute called John and he dropped by for a quick visit.

John Rider and Ute on site.

Lana Malloy and Don Perry Visit the Site, Too

Just as John and Ute were leaving, Bryan spotted Lana Malloy, one of the Council members with the City of Monte Sereno, walking on Via Sereno.  Lana was on VIa Sereno to review the sidewalk by Winchester Boulevard.  Given she had not seen our project site since construction started, Bryan took the opportunity to give Lana a quick tour.

Lana was on Monte Sereno’s Site and Architecture Commission before joining City Council in November 2008.  She was on the Site and Architecture Commission that approved our site development permit in July 2008.

Just as Lana was leaving, another Council member came by.  Don Perry had to review the same sidewalk area on Winchester so, after doing so, he was able to see our project site.

Monte Sereno council members Don Perry and Lana Malloy on Winchester Boulevard at Via Sereno.

Today was a huge milestone for our project.  Our structural steel is now in place, ready for the hollow core concrete panels.

Preparing for the Day

It was a perfect blue-sky, California day to place our steel columns and beams.  Not a cloud in the sky and a faint breeze to keep everything cool and comfortable.  Our 35-ton crane, from West Coast Cranes, arrived on time with the truck carrying our steel columns and beams.

Our crane, from West Coast Cranes, arrived on site promptly this morning to get set up.

The team from Larson Steel setting the bolt heights in the pockets for the steel beams.

The truck with our steel columns and beams arrived and is waiting on Winchester Boulevard.

35 ton crane from West Coast Cranes starting to extend its boom.

Note how the five outriggers are extended to level and stabilize the crane.

Having a large crane in place on a beautiful day appeared to be a trigger for visitors.  For example, Wes Wenger (Wenger Plumbing) came by as did Doug Ferannte (Los Gatos Glass).  Both had positive comments on our project as it continues to move forward.

Setting the Steel Columns in Place

The eight steel columns were set in place first, on the bolts that Bill Brown’s team embedded in the structural concrete on March 6, 2009.  These steel columns will support the steel beams.

First steel column coming from the truck.

Our first steel column being set in place by the crane, with Hector Guerra guiding it.

The last steel column is in place and the bolts are being adjusted and tightened.

Placing the Steel Beams

We have five steel drop beams that are supported by the steel columns and foundation wall.  These drop beams support two steel flush beams.

Moving the first steel beam from the truck to the site.

Hector Guerra directing the first steel beam placement over the window well.

Our 54 ft steel beam coming from the truck on Via Sereno.

Pete Larson's team putting our longest steel beam into place.

Hector guides the steel beam over the Wine Cellar into position, taking extreme care not to touch the feature concrete wall in the Atrium.

Moving the first flush beam from Via Sereno into the site.

Flush beam being lowered into place.

Our crane operator worked well with the Pete Larson's team, ensuring that the beams were placed in position gently and safely, exactly as directed. The owner of West Coast Cranes, Lowell Tucker came to our job site for a few minutes to observe the steel placement and ensure the work was going well (it was)..

First flush beam being positioned from the Atrium to the west foundation wall.

Placing the drop beam under the Dining Room and Kitchen. Note the crane operator is somewhat 'blind' as this beam is behind the Kitchen/Garage concrete feature wall.

Hector Guerra directing Pete Larson's on-site team.

John Rider Reviews the Steel Placement

John Rider (Jrider + Design), his wife Jenny, and Joel Lemons came to the site to see the steel beams being placed.  John was the focal point on our integrated design team as he ran the ArchiCAD model that was used to export and import DWG files from our design engineers to ensure all the components would ‘fit’ in our design.

John’s offices are located only minutes away on Hamilton Avenue in Campbell, California so they came just before going for lunch today.

We reflected on John’s site visit when the structural slab was poured using the boom pump truck, and smiled.

We had a several visitors come to see the steel columns and beams today.

John Rider (left), Jenny Rider and Joel Lemons watching from the observation deck as the steel beams being placed.

Our Structural Steel is in Place

With all the structural steel in place, the crane operator retracted the outriggers and secured the boom.  Then, he left the site.  Definitely a milestone event for us! 

Securing the boom and shutting down the crane.

Visits by Our Neighbors

After Pete Larson’s team and the crane left the site, we received a couple visitors.

First, Phil Knopf and his wife, Bonnie, came to the site.  They have lived in Monte Sereno, on the other side of Winchester, for more than 30 years and have seen significant changes in our community during that time.  We know Phil through his continuing leadership with Los Gatos Little League, where both our son, Nik, and daughter, Kate, play AAA and T-ball, respectively.

Although Phil had visited our site before, it had been some time and Bonnie had not seen the plans.  They were most interested in our project so Bryan gave them a thorough tour and explained the design features and energy-saving elements.  Phil and Bonnie were the first people to walk down the exterior concrete steps into the lower level.

John McLaren, a neighbor that lives four houses away on Daves Avenue, came to the site and walked the property, noting the changes since his last visit.  He used our new exterior concrete stair and avoided the water that was soaking our feature concrete walls.  Since inception, John has followed and supported our project.  He seems particularly interested in our Wine Cellar.

Another neighbor, Kel Marchbank (Marcal Construction), was on his Harley and visited the site.  Kel was over yesterday and saw the site before the steel was placed today.  He was impressed with the progress today and is looking forward to seeing the hollow core concrete panels being placed on Tuesday.

Our neighbors, Phil and Bonnie Knopf, visiting our site.

Bonnie Knopf liked the steel beams that we placed today.

Kel Marchbank stopped by to see the progress since his review yesterday.

 Bryan was smiling from ear-to-ear as he locked the gate.  It was a huge milestone today.

Everyone enjoyed another blue-sky, California day. It was warm and beautiful (for a winter day).

After receiving approval from the City of Monte Sereno, we ordered the rigid insulating foam today and scheduled delivery for Monday (there is adequate space at the front of the project site). As well, we scheduled the shotcrete lagging for Wednesday. This lagging will go on the east and west walls, and on the first four feet of the north and south walls.

With the lagging in place, the 40 psi rigid foam insulation will be placed on the 3/4 inch crushed rock and around the perimeter walls. Then, the waterproofing will on on top of the rigid foam insulation, forming the outer hull of the ‘concrete boat’. With the waterproofing in place, we can pour the three inch working slab.

Yeah, lots to do in a couple weeks. It looks like 10-day weather forecast has rain on Thursday (with 10% chance on Tuesday and Wednesday).

View of south-east corner of site with excavation for plumbing.

With the drains in place and connected to the sump pit, we’re now collecting water. Yes, the cover to the sump pit is screwed down safely.

Water collecting from pipes leading to the sump pit.

We met with our designer, John Rider, to review the exterior plans for the south-east corner of the house, which is starting to look quite busy and complicated. John’s firm, Jrider + Design, is now located in Campbell on Hamilton Avenue so he is only a few minutes away now.

Jrider + Design.

We were addressing the placement of the rainwater catchment system and how the various utilities enter the house from the street. With an underground cistern planned, the utilities cannot go straight into the house. Completing these details required calls to both our civil engineer, Casey Carlson, and our plumbing firm, Wenger Plumbing. As usual, John did his magic on the model (using ArchiCAD v12).

John doing magic with ArchiCAD v12.

Back to the site to button it up. The site is looking safe and secure.

Site secured with holes covered.