We thought we missed the PEX. Not quite …
One of the 97 holes that we drilled cut through one of the PEX loops, within 20 inches of the manifold. Fortunately, there will be a cabinet base that will cover the area where we removed the concrete to expose the cut PEX so we can repair it.
We were so close …
Close up of the cut. We will be able to repair this and it will be hidden under a cabinet.
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.
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.
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
It was great to celebrate yet another Thanksgiving with good friends. We went to the Staab’s to celebrate Thanksgiving this year. We’re planning (hoping?) to celebrate Thanksgiving in our house in 2010. Before enjoying dinner, we had some work to complete.
Bill Brown’s team completed placing the reinforcing steel in the lower level so we went to the site to finish the PEX. Our good friends, Paul Marcaccio and Laura Watson, were visiting from Toronto so Paul joined Bryan and Nikolas at the job site.
Bryan instructed Nik on how to use the nylon ties and then how to clip the excess off. Nik was a fast learner and was soon ‘picking rice’.
Bryan instructing Nik on how the PEX needs to be positioned and attached to the steel mesh and the reinforcing steel (rebar).
Nik working on the PEX ('picking rice').
Bryan tying PEX to the wire mesh under the rebar.
Paul bringing 'two bottles' of wine to the Staab's for Thanksgiving dinner. A Rombauer Chardonnay and a Ridge Zinfandel (2004 Geyserville).
Our smiling and very gracious hosts, David and Pia Staab.
David bringing the bird out of the oven - looks delicious!
The girls - Laura Watson, Donna Calise, Jo-Anne Sinclair and Leanna Staab.
With the PEX in place, Bill Brown’s team was back on the critical path.
They had to complete placing the reinforcing steel (rebar) over the PEX and form the perimeter where the concrete ends and the hardwood floor starts.
That said, the garage is complete and we’re pouring concrete tomorrow morning!
The first few pieces of rebar are over the PEX (and the 6-6-10-10 wire mesh).
The PEX is in place and pressurized to 100 psi.
Looking toward the North wall, you can see the layout of the PEX and how the first pieces of rebar are being placed.
The garage is completed and it will be poured tomorrow.
We got it done today – the PEX is in.
Since we have radiant heating (and cooling) in the house, we need to put PEX into the concrete. Our design was different in the ground floor as compared to the lower level.
On the main floor, we had to pour at least 3 inches of concrete over the hollow core concrete panels, as it forms a composite system (the concrete and the hollow core concrete panels). In those areas where we have hardwood floor, we will have 3 inches of concrete and 2¼ inches of hardwood flooring. Where concrete will be the finished floor, we will have 5¼ inches of concrete. In the lower level, we will have 3 inches of concrete where the concrete is the finished floor.
The reinforcing steel (rebar) is placed in the middle of the slab and we want the PEX close to the surface of the concrete. Thus, on the ground floor the rebar was put down first and then we attached the PEX on top of the rebar. In the lower level, where we have a 3 inch slab, our design is to put down 6-6-10-10 wire mesh, then attached the PEX to that. The rebar will go on top of the PEX.
Now that the concrete was poured on the ground floor, we cleaned up the debris that fell to the lower level and had to put in the PEX. Then, Bill Brown’s team could put in the forms and rebar.
Thus, the PEX is on the critical path.
Matt Jung sent one of his top technicians, Tom Rutledge, to install the PEX. Bryan was his helper.
Tom arrived at the job site on time and quickly assessed the situation. Bryan had just picked up the sheets of 6-6-10-10 wire mesh and we started.
We laid out the wire mesh evenly over the areas where the PEX would go, cutting it to shape and securing it with nylon ties. Then, it was time to start ‘picking rice’. This is the term used to describe the task of laying out the PEX and then securing it to the wire mesh with nylon ties. Just like picking rice.
It took most of the afternoon but we finished on time. It was satisfying to see the PEX in place, ready for the rebar.
There was light rain today, which is helping the concrete to cure slowly so it won't crack (we hope!).
The PEX is done! Note the neat layout of the PEX, on 12 inch centers. Next step is to put the rebar in and place the forms around the perimeter.
After a solid day of work, Tom had a big smile knowing we met the deadline to have the PEX in place so the rebar can go in..
It was another beautiful blue-sky California day today. Our goal is to complete pouring concrete inside the house before Thanksgiving so that means we need to have the radiant heating/cooling PEX loops inside the concrete before each pour.
We need to pour concrete over the hollow core concrete panels in the living area and the garage on the main level, and then pour three inches of concrete in the lower level. On the main floor, there will be 3 inches of concrete everywhere and 5.25 inches of concrete where we are having exposed concrete. The other areas will have hardwood flooring in a 2.25 inch system (3/4 inch subfloor, 3/4 inch PEX layer, and 3/4 inch hardwood flooring).
Bill Brown was confident that his team wouldn’t be on the ‘critical path’ and that the radiant heating/cooling (PEX) would cause delays in meeting the Thanksgiving deadline.
The gauntlet was thrown …
Several month ago we started working with Ken Martin of Silicon Valley Mechanical to design the radiant heating and cooling, and the displacement air ventilation. Ken is a Professional Engineer and has extensive experience with innovative projects, including David Kineda’s Z-squared building in San Jose, which David won a USGBC Northern California chapter award for (and was presented at the USGBC NorCal Gala on 10/30/09).
We had engaged Monterey Energy Group for the initial design of the radiant layout, which they did. After meeting with Ken and reviewing the preliminary design with him, Ken identified a number of innovative improvements that could be made in a cost-effective manner that would allow for simultaneous radiant heating and cooling across zones as well as heating the swimming pool and cooling the wine cellar.
The highlights of Ken’s design changes included:
Matt Jung from 88HVAC met Bryan at the project site and showed him how to take the PEX off the spool and lay out the PEX. Matt has extensive experience with radiant heating and this will be his first radiant heating and cooling project.
We are tying the PEX to the #3 reinforcing steel (rebar), which is placed 18 inches on center each way. Bill Brown cautioned us to ensure that no PEX loop should be able to ‘float’ upward as he will be doing saw cuts to control the cracking in the slab. With the PEX loops pressurized to 100 PSI, Ken Martin believes that we should be OK. Bill would have preferred to have the PEX under the rebar; for performance purposes, we will be placing the PEX on top of the rebar so it is closer to the surface (but safe from the saw cuts).
A perfect beautiful blue-sky California day to start laying out our PEX.
Before Matt arrived, Bryan used our shop vacuum to clean the debris from the perimeter voids around the hollow core concrete panels.
Matt working with Bryan to lay out our first PEX loops and zip tie the PEX securely to the rebar.
