We’re moving ahead on many aspects but lagging on others.  The penetrations of the concrete floor and roof have long been on our critical path and one area that we have been lagging.  We engaged Lorna Fear of Visual Cue Thermal Imaging to help us, again.  Installing Schneider Electric’s Whole Home Automation Solution is moving forward rapidly.

Penetrations through the Concrete Floor

We need to core though our concrete floor for various plumbing, electrical, central vacuum and other services to go from the ground floor to the lower level.  We anticipated these penetrations and then made some design changes.  During the construction, we put PEX into the concrete for our hydronic heating and cooling.  With the design changes, we must ensure that when coring through the concrete we do not damage the PEX.

Although Bryan took measurements of the PEX before we poured the concrete floors, the PEX could have moved slightly and the risk of damaging the PEX, while low, has a very high cost to repair.  Consequently, we decided to take Wes Wenger’s advice and circulate hot water through the PEX and use thermal imaging to confirm the location of the PEX in the concrete.  Thus, we could be very confident that while coring the concrete we will not damage the PEX.

Setting up the thermal imaging required a number of steps.  First, Wes assembled a pump that could be connected to the PEX so we could pump hot water though the system.  We used hot water from our rental house, and we had to connect a hose to the hot water heater and fill clean plastic 35 gallon garage pails with the hot water and then transport them to the job site.  The hot water had to be circulated through the PEX and increase in temperature.  Then, Lorna could take the thermal images that would identify where the PEX was located.  Lorna had been to our project site on August 20, 2010 to take thermal images of our roof structure, and she identified where there were voids between the SIPs.

We got it done by 10:15 am.

Installing the Electric Distribution Panels and Lighting Control Panels

At the same time, Al was busy installing the electric distribution panels and lighting control panels in various locations in the house.  We have a 400 amp combined service entry device, which holds our electric meter from PG&E.  From there, electricity is distributed though four load centers inside the house.

The East Mechanical room has a 200 amp panel and a 100 amp panel.  The West Mechanical room has two 100 amp panels.  Our lighting control system has three locations – the Upper Laundry room (1 panel), Air Handler room (2 panels), and East Storage room (3 panels).

At this stage, Al is putting the panels in place so we can start to run the wires (conductors) between the panels.

It is coming together nicely.

Wes Wenger circulating hot water through the PEX to prepare for the thermal imaging.

Lorna Fear, of Visual Cue Thermal Imaging, using her Fluke infrared thermal imaging camera to identify where the PEX is located in our concrete floor.

Mapping the PEX in the concrete.

The picture-in-a-picture thermal image, showing where the PEX is embedded in the concrete.

Lorna, with her Fluke infrared thermal imaging camera, identifying exactly where the PEX is in the concrete.

Thermal image showing the temperature differences that identify where the PEX is embedded in the concrete.

Wes measuring to identify where the penetration through the concrete would be for the tub drain.

Inside the East Mechanical room, showing the 200 amp distribution panel (right) with the two non-fused disconnects mounted under the embedded connection box. There will be another 100 amp panel mounted on the left side and the transfer switch will be mounted on the cover of the connection box.

The lighting control panel inside the Upper Laundry room. This is a large penetration of the shear wall so we will transfer the shear to the other side of the wall (in the Atrium).

Atrium side of the shear wall, which will be covered with 1/2 inch plywood and then sheet rock.

Three lighting control panels, mounted in the East Storage room. These panels will contain the components of Schneider Electric’s Whole Home Control Solution.

Two more lighting control panels, located in the Air Handler room.

We had Penhall Company out again today to core drill some important holes in our concrete walls.  In order to close our remaining open trenches, we need to bring electrical services into the East Mechanical room.  As well, we have to get our plumbing and electrical into the East Mechanical room from inside the house.

Theron Boulden, from Phil Murray Construction, was on site all day working on the 24 ft sliding glass doorway in the Living Room.  Also, Theron continued working on the sliding glass doors to the Wine Dining and Wine Cellar. We believe the sliding glass door could be installed tomorrow (Wednesday).

Al and Nep worked on tweaking the framing in various locations, in order to accomodate the core drilling and other requirements.  During the day, they ‘floated’ and helped with the core drilling (setting up the scaffolding), sliding glass doors (setting up the concrete cuts and actually cutting the concrete, and cutting recessments in the concrete walls for the Wine Cellar sliding glass doors).

Although Bryan met with Nathan Merrill, of American Ornamental Iron, he wasn’t able to order the FSB hardware for the front door.  We’re still waiting to receive two quotes on the hardware.  Bryan did, however, order the four Soss invisible hinges for the front door.

Core Drilling the Walls

We need to connect waste water drains and plumbing vents through the wall from the East Mechanical room to the soffit on the East side of the house.  Thus, we need to have a penetration through the interior concrete wall to allow the pipes to pass through. 

In addition, we need three penetrations through the exterior foundation wall in the East Mechanical room.  One of these penetrations is for a 1-1/4 inch copper water supply pipe (from San Jose Water) and the other two penetrations are for data and electrical conduits.

Bryan reviewed the plans for the electrical and conduits with his father, John Mekechuk, when Bryan was in Edmonton last week.  John, a Civil Engineer, thought the plans were acceptable in California and approved the design.

Coring through a vertical surface requires the identical technique that Bryan used when coring the shotcrete test panel (on 03/26/09).  Although we considered doing the coring ourselves, engaging Penhall Company to do the coring brings their entire suite of equipment, including all the core bit sizes.

The technician from Penhall Company arrived earlier that the scheduled 10:00 am start time and left in his truck at 5:45 pm.  He put in a good day of work.

Coring a small 1-inch hole in the concrete floor for water supply.

Marking the hole in the East Mechanical room.

East Mechanical room, showing rebar and condult, taken on April 4, 2009.

Drilling the hole to support the core drilling rig.

Attaching the core drilling frame to the concrete wall.

Attaching the motor to the rig ...

Starting to core drill the first hole.

Drilling to depth, but not through yet.

Using an extension to drill through the exterior shotcrete wall (4 inches thick in this location).

Core drilling the third of three holes in this location.

Three holes cored through to the exterior. And we didn't hit any electrical conduit! Way cool.

Coring through the interior concrete wall to the East Mechanical room.

Completed coring through the interior concrete wall.

10-inch hole for plumbing to pass through the interior concrete wall into the East Mechanical room. This will allow Wenger Plumbing to complete the rough in on the East side of the house.

We’re getting our project back on track.  We are continuing to working on the roof (so we can install the windows), and also starting to backfill our open trenches (versus digging more trenches).

Agreeing on the Trenching

We wanted to ensure PG&E approved our trenching strategy before digging too much.  Our project coordinator, Nathan, came to the job site and reviewed the electrical conduit that we uncovered.  He saw the water pipe (from San Jose Water Company’s meter, and agreed that it would be ok.

After the City of Monte Sereno inspects the water connection behind the meter, we’ll be able to backfill the trench from the water meter to the cistern trench.  Filling this trench will provide some much-needed real estate.

Identifying the Roof and Floor Penetrations

We can’t put our roof membrane on until we identify and make all of the penetrations through the flat roof.  The penetrations of the roof are for plumbing, dryer vents and exhaust fan vents.  The most complicated are the plumbing vents as we want to limit the number of penetrations of the roof.

Wes Wenger, of Wenger Plumbing, arrived at the job site and walked through the various plumbing fixtures that we will have.  As well, Greg (‘G-Man’) went through all of the penetrations with Wes.  Yup, Wes makes the promises and G-Man has to deliver on those promises.  It was good to establish the vents and penetrations.

We (Jo-Anne and Bryan) need to establish where the free-standing bathtub will be located in the Master Bath, as the tub drain needs to be drilled through the concrete floor.

Also, we need to get Kate’s soaking tub as this drain needs to be established, too.

Finishing the Skylight Curbs on the Lower Flat Roof

Francisco and Carlos continued working on the curbs for our Velux skylights.  This was their second day on this task and they were able to finish it off.  Bryan sent the exact locations of the skylight curbs and dimensions to Leo at Johns Manville so he could complete the shop drawings. 

Leo promised an updated layout on Monday morning, with shop drawings by close of business on Monday.

Backfilling and Compacting the Sewage Trench in Front of the Garage

With the pipe that will take the Lifesource Water Filter backwash water to our cistern stubbed out, we could now backfill and compact the sewage trench immediately in front of the garage.  This trench has been particularly irritating since it limits our movement into and out of the garage.  Plus, it looks messy.

This item was completed today.

Hosting a Friday Night Flamingo Event on Vista Avenue

As with other neighborhoods across the U.S., our neighborhood on Vista Avenue (plus Bruce Avenue and Kavin Lane) has a long-standing tradition of ‘Flamingo Nights’.  On the first Flamingo Night of the year, we signed up to host the July 30 Flamingo Night.

Kate, Sierra and Carli worked on decorations, and Jo-Anne and Wendy hung up our Flamingo lights over the garage.

Our project coordinator from PG&E, Nathan Lee, reviewed our trench from the San Jose Water Company meter to our house. He approved the location as the trench did not interfere with the PG&E natural gas or electric lines.

Wes Wenger (left) and Greg ('G-Man') review the plumbing plans while establishing the locations for the plumbing vents in the SIP roof and the coring through the concrete floor (drains, hot and cold water supply, and vents from the lower level).

The completed insulated curb, which will have a sloped cover and support the Velux skylight.

The backfilled and compacted trench in front of our garage. Finally done!

Our table is ready to host the Friday Night Flamingo on Vista Avenue. Note (right to left), Kate, Sierra and Carli are working on the decorations.

Jo-Anne found some excellent Flamingo lights several weeks ago, so Wendy and Jo-Anne strung the lights up for the event.

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.