Addition Progress Report, Week 29

AddnSiding

The addition siding has been going up, slowly but surely.

AddnSiding2

The clean lines of the addition make the old roof look pretty sad. When (If ??) the addition is done we will probably go ahead and replace the roof on the old house so the entire roof is the same age.

AddnWallboardVestibule

This is the view of the inside of the vestibule.

AddnWallboardVestibule2

We recycled the vinyl replacement windows from the old addition.

AddnWallboardBowWindow

Here you can see the fanned ceiling in the bow window is almost done.

Also, some of the plumbing has been roughed in and most of the basement wallboard is up, but pics will wait for another day.

Addition Progress on the Inside

Over the holidays the roofers completed the metal roof, and the insulation sub did round one on the inside of the exterior walls: sprayed 1" closed-cell urethane foam followed by fiberglass batts. Then last week the general contractor crew came in and did some wallboard. They did what they could while still leaving space for the plumber, who has been delayed. Once the plumber is done with his rough-in, it can be inspected and then the wallboard can be completed and then the insulation as well. This week (once the ice melts) the siding sub will start putting up the HardiePlank siding.

AddnWallboardPano1

A panoramic view from the loft of the insulation and wallboard.

Addition Progress from the Outside

Christmas Eve day was busy around here with four different construction-related visits: framers, to complete a few odds and ends; electrician, ditto; a debris-removal visit; and an inspector, who OK’d the framing and electric. The day before the roofers got started on the metal, as seen below from the pasture.
AdditionFromPasture

Goats Kids 2015, Early Edition: Two More

2015Kids_TwoMore_2014

Two more goat kids in past several days. Since kidding is early we are very grateful that it has been relatively mild weather.

2015Kids_Second_2014

Goats Kids 2015, Early Edition Rounds One and Two

For unknown reasons.

For unknown reasons, our rutting season started early this year, so our 2015 crop of kids has already begun. Here are the first two, one born this morning (the tawny one in the back) and the other a couple of days ago. Both first-time moms seem to be doing OK — we have them locked ion the southern portico of the loafing shed with their kids to encourage the bonding process.

The kids are under the attentive watch of our sole remaining chicken — the rest were killed in a series of fox attacks in the early fall, and this one decided to move out of the hen house down in the obviously dangerous meadow paddock up to the loafing shed with the the goats and the dogs. She lets the goats kids play with her … well at least she tolerates it much better than when our dog Bersheba “plays” with her.

Addition Progress Slow But Real

Well, for the past month there has been progress. All the windows and exterior doors are in place. The first round of electric wiring rough-in has been done. The roofers should be here (maybe this week) to put the metal roof on. Next up is the plumber.

AdditionFromLoft

From the loft, looking down on the east-facing bow window and the sliding glass door onto the lower veranda. The electric rough-in has been done. In the foreground you can one of the two required floor outlets by the future loft railing. In the distance you can see the wood blocks supporting the great room outlet boxes — we are putting most of the wall outlets near the floor in the extra-wide baseboard.

Addition Windows Start Going In

AddnSomeWindows

As this work week draws to a close, the addition ends up all the West windows in place and some of the North windows as well.

Taking Real Shape

AddnSheathingEast

The new addition is really taking shape as the sheathing goes on. This is the view of the east (back) side of the house from the pasture.

AddnSheathingWest

The west (front) side.

Addition Update: Roof Trusses

Been busy around here the last week and a half.

AddnLoftFraming

Last week they continued with the framing. The loft sub-floor is in place since it ties in with the exterior wall framing. The windows were a bit of a challenge to line up with the existing house windows — we had to go code-minimum with the headers.

AddnFutureBayWIndowView

A preview of the future view from the bay window.

AddnTrussesUV

The roof trusses arrived yesterday. This is the view from the upper veranda yesterday afternoon. In the upper left you can see that the tops are flat. There is a peaked cap that will be added — the trusses would have been too big to truck in if they had been one piece.

AddnChimneyPointed

Concurrently, the masons finished up pointing the chimney. It’s a little hard to see in this picture, but the mortar at the bottom is darker because it is fresher, the mortar at the top was done last week and is closer to the lighter finished color that we chose.

AddnTakingShape

The view from the pasture.

Addition Framing Begins

Framing_Begins

The first day of framing on Thursday saw the first floor east and west walls go up. With a little luck, this week should see roof trusses in place.

Ready for Framing

Over last weekend I used a pressure washer to blast the parging off of the chimney. It was wet, gritty, chilly work. The contractors came back yesterday and finished up the sides and cleaned up the debris.

Chimney1

Ready for day 1 (Saturday)


Chimney2

Ready for day 2 (Sunday)


Chimney3

Done on Tuesday. Looks pretty good — now it needs to be pointed up and then sealed. That will happen concurrently with the framing.


Framing_lumber

This afternoon the lumber for the exterior wall framing arrived. The timing could have been better, since it interrupted the back-filling around the north side, but it is a sign of progress nonetheless. Framing should start tomorrow, and the roof trusses have been ordered and should come next week.

Polystyrene, Rebar, and Concrete

The main floor of our new addition is a suspended concrete slab (i.e., a slab that is not in direct contact with the ground.) We are using the LiteDeck ICF system for this slab.

LiteDeckBase

The LiteDeck system starts with a base layer of 6″ thick expanded polystyrene (EPS) with imbedded steel C channels (both for strength and to provide a way to screw on the basement drywall ceiling). It is shaped with a beam pocket 6″ W x 4″ H every 2′.

LiteDeckTopHat

Then foam “top hats” (4″thick in our case) are added to deepen the integrated concrete beams to 8″ H x 6″ W.

LiteDeckRebar

Next is the rebar. Lots and lots of rebar: Two ¾” pieces along the bottom of each beam, two ½” pieces along the top, ½” U-shaped cross pieces to help hold the length-wise bars in place, topped with a 2′ x 2′ grid of 1/2″ to stiffen the slab.

LiteDeckReady

Ready for concrete. The rebar is all wired together as a unit. The foam pedestals are for running plumbing and electric through the slab. You can also see the sole plate at the edges – the outside band is temporary bracing. The wooden box-like protrusion on the left is the where the basement stairway will go, the one on the right is for our dumbwaiter.

MainFloorFirstPour

The result (as poured yesterday.) The slab is around 4½” thick. At the top is the vestibule, a 3-season unheated room that also serves as an airlock for the addition entryway. To the right is the cantilevered floor of the bow window.

As I type this the plumbers are here to run a new well pipe through the previously-installed conduit that runs through the foundation. Once inside, it is going to temporarily run through the dumbwaiter window and reattach to the existing house plumbing. Later, we are going to relocate all the plumbing mechanical (pressure tank, de-acidifier, water heater) into the addition’s basement mechanical room. But for now, this will keep the pipe from freezing this winter and allow us to finish back-filling around the north end of the new foundation where the well is.

Next week, the exterior wall framing should begin. The bottom of the wall will be triple-plated so that when the exterior shell, including roof, is in place we can pour the final 4″ of concrete for the final floor. Before that happens, though, I will be running the heat tubing that will end up embedded just above the middle of the 9½” thick floor slab.

New Addition Update, Month 3

It has been almost a month since my last post about our new addition. Work has been proceeding, albeit slowly at times. It was always a long-shot that we would be (mostly) done by winter, and that long shot is missing widely. Now our sights are set on getting it under roof and closed in (windows/doors would be great but sheathing/house-wrap would be OK) this fall.

Last week and this week things have been moving along at a good clip. As I type, they are finishing installing the LiteDeck IFC for the main floor concrete slab. I will put up another post detailing that process in a couple of days.

Here is chronology of the past month or so of work, as of the end of last week:

The ICF blocks start to go in. In the foreground you can see the ladder-like Form Lock grids that are placed horizontally inside the ICF every couple of courses to help keep things straight and in line. There is lots of vertical and horizontal rebar in there as well.

The ICF blocks start to go in. In the foreground you can see the ladder-like Form Lock grids that are placed horizontally inside the ICF every couple of courses to help keep things straight and in line. There is lots of vertical and horizontal rebar in there as well.

Door and window openings being formed. Waterproofing film applied.

Door and window openings being formed. Waterproofing film applied.

Ready for foundation concrete pour. The metal studs sticking up along the outside perimeter are for attaching the foam boards that will surround the main floor concrete slab. You can also see the support scaffolding around the inside of the foundation forms.

Ready for foundation concrete pour. The metal studs sticking up along the outside perimeter are for attaching the foam boards that will surround the main floor concrete slab. You can also see the support scaffolding around the inside of the foundation forms.

The foundation concrete has been poured in the ICF – that process went pretty well, just had one corner start to separate which was field-braced without further problems. The BobCat is bringing in gravel for under the basement slab. To the left you can see three footers for the posts that will support a steel I-beam. To the right, on top of the foundation, you can see where they moved our temporary well pipe off the ground so they could re-grade around the back of the foundation so the equipment has room to maneuver.

The foundation concrete has been poured in the ICF – that process went pretty well, just had one corner start to separate which was field-braced without further problems. The BobCat is bringing in gravel for under the basement slab. To the left you can see three footers for the posts that will support a steel I-beam. To the right, on top of the foundation, you can see where they moved our temporary well pipe off the ground so they could re-grade around the back of the foundation so the equipment has room to maneuver.

After the gravel and floor drain pipes were done, I took over to prepare the basement underfloor heat tubing. The first step was putting down 2" extruded (XPS ) foam board for insulation. Note the square cutouts for the I-beam post foundations.

After the gravel and floor drain pipes were done, I took over to prepare the basement underfloor heat tubing. The first step was putting down 2″ extruded (XPS ) foam board for insulation. Note the square cutouts for the I-beam post foundations.

Then, based on my heat tube layout drawing (drawings  available here) I snapped some chalk lines, installed my 200 screw-in tubing clips, and started snapping in the 5/8

Then, based on my heat tube layout drawing (drawings available here) I snapped some chalk lines, installed my 200 screw-in tubing clips, and started snapping in the 5/8" PEX-a heat tubing.

Basement heat tubing all in place. I had to make some adjustments to go around the post foundations, but otherwise I came out just a little short of my original drawing. For the sake of economy and availability I used a 300' roll of tubing for the 300' basement run. For the main slabs three 300' runs I have a 1000' roll, so I will have a little slack. And, since I knew all four tubing runs would be a little different in length, I bought a manifold that includes flow control balancing valves.

Basement heat tubing all in place. I had to make some adjustments to go around the post foundations, but otherwise I came out just a little short of my original drawing. For the sake of economy and availability I used a 300′ roll of tubing for the 300′ basement run. For the main slabs three 300′ runs I have a 1000′ roll, so I will have a little slack. And, since I knew all four tubing runs would be a little different in length, I bought a manifold that includes flow control balancing valves.

Then they put rebar on top of the heat tubes. This not only adds strength to the slab but also insures that the heat tubes won't pop out and float to the top of the concrete.

Then they put rebar on top of the heat tubes. This not only adds strength to the slab but also insures that the heat tubes won’t pop out and float to the top of the concrete.

The basement slab pour was perfectly uneventful, just the way all concrete pours should be. After the concrete cured for several days, they built the load-bearing basement partition wall and installed the I-beam, arriving here by crane truck.

The basement slab pour was perfectly uneventful, just the way all concrete pours should be. After the concrete cured for several days, they built the load-bearing basement partition wall and installed the I-beam, arriving here by crane truck.

Then some temporary bracing walls went up – these will need to stay in place for 3 weeks after the main slab pour.

Then some temporary bracing walls went up – these will need to stay in place for 3 weeks after the main slab pour.

Then they started laying the LiteDeck ICF. This is an aerial view of the base layer installation in progress.

Then they started laying the LiteDeck ICF. This is an aerial view of the base layer installation in progress.

Next up: Completing the LiteDeck by shaping the bow window, adding the top hats, adding the perimeter foam and first-course footer board, and adding plumbing/wiring chase-ways. Then, the main floor pour.

Aerial View

I had another session with my flying camera yesterday afternoon. I am still working on getting comfortable with the controls, so the video composition is not great, but below is an 11-minute aerial view of our farm. By the way, the return and landing was handled by the drone’s “failsafe” auto-pilot.

Addition Foundation Forms

Well, after a series of frustrating delays, the foundation (basement wall) forms are ready for concrete. I also treated myself to a fancy new toy: A DJI Phantom Vision 2 Plus quadcoptor drone – a flying camera!

DJI Phantom 2 Vision+

DJI Phantom 2 Vision+

I just started flying it yesterday, here is a new perspective on our construction — bonus points if you can spot the millstone (transported, we believe, 1/4 mile from Hooks Mill to our property by the 1936 flood), and our herd of goats. (If you have the bandwidth, it looks best fullscreen in HD.)