We are getting closer to putting the tapered insulation down on our flat roofs so we can put the membrane on and get water tight.  Before doing so, we verified that the SIP roof has no ‘voids’ in the insulation where the individual pieces come together. 

In anticipation of the next step, becoming weather tight, Bryan picked up the first of 72 boxes of windows so we could confirm the window preparation requirements.  Since we will be seeing Carole Murray tomorrow, it is important to show that we’re progressing and getting the windows out of her warehouse!  Also today, Bryan continued working with Izzy on ensuring the HDPE coming out of each concrete pier can be joined to create our ground loop.

At the end of the day, Gino Attanasio from White Cap dropped off two more 10-lb containers of expanding foam for us to use in tightening up our building envelope.

Picking Up Our First Window

We have 72 boxes of sliding glass doors and windows at Murray Window and Door.  We can’t install the sliding doors and windows until we are weather tight.  Well, we probably could install them but we are choosing not to.

In anticipation of the first clerestory window installation, we picked up one of the 16 windows.  This will allow us to identify exactly how the windows will ‘fit’ and how we will need to attach the windows.  While we have shop drawings, it is always good to have the actual item on hand to avoid potential problems.

After hoisting the window up and onto the roof, we were able to see exactly how the clerestory windows will fit.  This was important as we may have a conflict with the nail fins and edge trim in each of the four corners where the two clerestory windows come together.

Using Thermal Imaging to Verify Our Insulation Value

In our house, the SIP panels are connected on the roof with either wooden I beams or 6×12 splines.  In either case, there is a possibility of leaving ‘voids’ in the EPS foam at these locations.  If a void is left then the insulation value of the roof is compromised.  Voids will reduce the insulation value much more than thermal bridges, which is another problem that we want to avoid.

Today, we took the opportunity to engage Lorna Fear, with Visual Cue Thermal Imaging, to spend a couple hours going through our project to verify that we didn’t have any voids between our SIPs.  Bryan and Lorna worked together, with Bryan explaining how the SIP construction worked and Lorna reviewing the thermal images and identifying where potential problems could be.  Lorna is an expert at interpreting the thermal images and ’seeing’ where there are inconsistencies in the building envelope.

The thermal imaging identifies different surface temperatures and displays those differences with different colors.  Since heat goes from hot to cold, a surface temperature that is colder than surrounding surfaces may indicate that the energy is being drawn into the building, through a less-insulated condition than the surrounding area.  However, surfaces may also reflect thermal energy, thus showing very ‘hot’ surfaces that may hide other problems.

Given her experience, Lorna can identify where potential problems may occur with our insulation.  Bryan asked Lorna to identify all potential problems locations as we can deal with ‘false positives’ at this stage.  If we miss a problem, it could be there for the life of the building.

Removing Concrete for Our Ground Loop

Bryan spent the afternoon with Izzy chipping away at the top of 6 of the 12 concrete piers on the West side of the house.  Ken Martin, from Silicon Valley Mechanical, fine-tuned the design of the geothermal ground loop so there are two ground loops on the West side that include six concrete piers in each ground loop.

Connecting the individual loops in each pier requires two 90 degree fittings and a short length of HDPE.  Then, the piers need to be connected to each other in a daisy chain manner, with a supply and return for each pier.  For the physical connection, Matt Jung (88HVAC) identified that we need a one-inch space for the cold ring and then another 4 inches to weld the fittings on.  Thus, there must be at least five inches of clear space on the top of each concrete pier where the connections will be located.

All of the piers need to be checked for sufficient space and, where additional space is required, the concrete must be removed.  Removing concrete is noisy, difficult and time-consuming (just ask Bryan). 

Picking up the first of 72 boxes from Murray Window and Door. Bryan was smiling as he picked up the first box, especially since we will be seeing Carole Murray on Saturday afternoon at Black Ridge Vineyards.

We have the window on the roof, and unpackaged it so we could see exactly how it fit and what the potential issues would be when installing it (and the other 15 clerestory windows).

Lorna, using her Fluke infrared thermal imaging camera, reviewing the South side of the South Gable over the Master Suite.

Lorna uses her Fluke infrared thermal imaging camera to review the upper flat SIP roof for voids.

This is the thermal image with the surrounding image around it. You can see the surface temperatures with the scale on the right hand side.

Lorna using her Fluke infrared thermal imaging camera, identified potential locations where voids may be on the upper flat roof that need to be investigated.

On this thermal image you can see where the warm and cool locations are. This thermal image shows that there may be voids between the SIPs that need to be filled with expanding foam.

Izzy and Bryan spent several hours removing concrete from the top of the concrete piers so the ground loops can be connected by 88HVAC. Matt Jung of 88HVAC will be coming by the job site on Sunday to verify if additional concrete needs to be removed.

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.

We have been working with Carole Murray and Annie Rouse of Murray Windows & Door, Inc.  Carole and Annie came to the job site today to review where we are and do some field measurements.  Also, today is the final preparations before we pour concrete in the lower level tomorrow morning.

Carole Murray and Annie Rouse Visit Our Job Site

After meeting with Carole and Annie in their offices in Campbell, Bryan suggested they come to the job site and review the openings for the sliding doors and windows to see the issues first hand.  Although we have computer renderings of the house from various angles, there is no substitute for seeing the scale and connections in person.

Carole has suggested that we change the bifold patio door system that is at the back of our house to a large sliding glass pocket door.  This pocket door will go behind our feature concrete wall in the dining room.  We need to confirm the details on how this will work.  In addition, we will have to submit revised plans to the City of Monte Sereno as this will increase the size of the house by approximately 12 square feet.

Carole Murray (right) and Annie Rouse (left) reviewing the job site.

Annie taking notes.

Final Preparations Before Pouring Concrete Tomorrow

it seems there are always last minute things to do before pouring concrete.  Or, it seems like Bryan leaves things to the last minute.

The two remaining items were for Bryan to (1) insulate the PEX where the supply and return lines come together near the manifold; and (2) take photos of the PEX that will be embedded in concrete. 

Insulating the PEX increases the performance of the system by allowing the supply line (hot) to be insulated from the return line (cold) so the hot water in the supply line is not cooled by the cooler water in the return line.  This important task was easy to do and only took a few minutes.

Taking photos was simply a matter of going around the perimeter with the measuring tape and camera. 

With these two items completed … let’s pour concrete!

Lights on, looking left ...

Looking center ...

And, looking right.

PEX in place by the Snack Area (exit sliding door on the left).

Insulated PEX in concrete in Nik's Room/Lower Powder Room.

PEX coming into manifold in the West Air Handler room. Note the insulated PEX.

The