Tag Archives: Construction

CONSTRUCTIVE TRAVELING: Windows to the World (Weeks 36-39)

This month’s activities includes installation of windows, building the stair between two levels, and waterproofing of the exterior skin. Both the roof and exterior walls need good moisture protection, so additional care is being taken to check details with a waterproofing consultant.

Delivery of Exterior Windows

In addition to interior wall framing, shear walls between the existing house and new addition have been added. You can see a portion of the wall along the stair to the right in the photo below. In the next photo, deck rails have been built. The roof parapet will be built next, providing protection for a future deck and extending the roof approximately 42″.

Miscellaneous windows and exterior doors were ordered, and planning for interior finishes and equipment went into high gear. While we thought that ordering materials and products would create issues with delivery and material availability, the problem was not as great as imagined.

There are always alternatives if you are flexible about the products, and since we were not providing custom or high end finishes, we could work around lead times and locally available products. Out of the items for kitchen casework through Ikea, appliances through a discount broker, and plumbing accessories appear to be within reach, at least at his point before actual ordering takes place.

Wind rather than rain is a deterrent to working on site. The gusty coastal weather has been downright unpleasant at times and chills you to the bone. We can’t wait for the autumn weather when the winds die down, although we may be in for some unpredictable air quality from fires.

With the existing kitchen and dining room out of commission, it has been a challenge to prepare and eat meals. On top of that, the ambient temperature in these rooms average around 50 degrees. The heating bill was over $700 last month until we realized that the exposed air was sucking all the heat out and the thermostat was registering the coldest past of the house!

Felix has lost his viewing stand from the dining room window and can only wistfully catch glimpses of Mom and Dad during bathroom breaks or snack sneaks. The roof obscures all the active work taking place inside the new space, so there’s no opportunity to view activity from above when roof joists were previously open and exposed.

As an alternative, Felix has watched street construction down the block. His beloved dump trucks, bulldozers, and and excavators are all readily available in full operating splendor during his daily strolls. They complement his readings from favorite construction books. He never tires of hearing them again, even on the sixth or seventh time in a row.

CONSTRUCTIVE TRAVELING: Completion of Phase I Foundation Work (Week 17-19)

Newly completed slab showing where the entry to the unit will be located

Our ground floor slab has been completed! In the photo above, me (and my shadow) are standing on the ground floor where the living/dining/kitchen space will be located. I am facing the new entry area where I will be greeting you at the door. You will be waiting outside, where the gravel is shown!

We were very relieved to finally see the results of the foundation work after several months of hand wringing. As with all construction projects, you somehow reconcile the realities of time and budget. Expectations always exceed reality, and you are forced to make some hard decisions. You learn a lot about the business of construction, the players, and the many moving parts that come into play. You come to accept and live by those hard choices that had to be made.

Difficult conditions on a small sloping site created challenges for the foundation crew. While most of the pier drilling went smoothly, there were a couple of stubborn piers in the middle that refused to cooperate. These were clearly aggravating the drilling crew, yet they pursued and prevailed. At times, no one wanted to breathe for fear of causing a collapse of the openings.

Aware of their concerns but unable to affect any change to the site conditions, I watched from the dining room window. The crew hacked away at the sandy soil, drilled through and extracted dirt and rock, force-fed the steel casings, lowered the reinforcing cages (some 30′ long), and injected the concrete.

We watched this dramatic choreographed performance unfold each day. The huge drill plowed within inches of our window. At times, I thought it would smash the window or crash into the side of the house! The exposed wall of the kitchen concerned us as a few leaks threatened to derail our comfort, and a few vibrations kept us wondering whether we were going to be shaken into homelessness.

As it stands, the foundation crew knew exactly what they were doing, where to place their equipment, and drill the holes. I was grateful to the care and precision they used. Their expertise is the lynchpin of the project.

The concrete work for the retaining wall went quickly following the pouring of the piers. Before we knew it, the slab was topped out after the layers of gravel, foam insulation, moisture barrier and rebars were set over the backfill. We could revel in the delight of finally “getting out of the ground” and declared the first phase of the ADU completed.

Phase Two Construction of Rough Framing has officially begun, with the deck supports being tied to the retaining wall. The deck framing will provide a work space for the ADU construction when framing work begins. Interior finishing will complete the project during Phase Three.

Recap of Phase I Foundation Work

This video represents a year’s end celebration of our work and efforts toward building the ADU.


We hope you have enjoyed following the journey building the addition to our house. We wish everyone a safe and joyous new year. Let’s look forward to the great new adventures ahead for all of us!

CONSTRUCTIVE TRAVELING: How to Retain Your Form(work)—(Weeks 9-16)

While the previous two months seemed to drag with the drilling of the piers, there was a lot more to observe during these two months of construction of the ADU (Accessory Dwelling Unit). As the structure lifted itself from below ground, we could witness progress of the construction. We were gratified by physical signs finally appearing after two years of planning and design!

Formwork

Temporary formwork was built for a concrete retaining wall and grade beams along the perimeter of the addition. There seemed to be as much, if not more, effort put into the construction of the forms than the pouring of the concrete itself, which seemed easy after the complex engineering and layout of the entire space. Needless to say, all of the work that will ultimately not be visible—the drilling of the 30 foot piers, the intricate network of rebars, the wooden formwork that holds the wet concrete—is just as essential as what one sees.

Once the concrete was poured, the formwork was removed. It was sad to see all the hard labor put into its construction disappear so quickly.

House of Sand and Fog

Next, the sandy soil made its reappearance on the site. The backfill was compacted into the large bowl created by the concrete walls.

Layers of Icing on the Cake

Within one week, the finishing touches and crucial layers of protection under the floor were added: 6” of gravel followed by a 2” layer of insulation. Finally, the moisture barrier (yellow plastic material) was added to the underside of the slab.

Dear Little Felix had a field day watching all of the activity, keeping him entertained throughout the day. Watching and learning outside our window was a great home-bound alternative to traveling around the world to see the sights!

CONSTRUCTIVE TRAVELING: ABS OF STEEL AND CONCRETE SOLUTIONS (Weeks 5-8)

The Dining Room Window gives us a front row seat of the ADU (Accessory Dwelling Unit) construction in our back yard. For much of the last two months, it felt like watching the grass grow at times, and sudden operatic performance at others. There was plenty to consider, ponder, and worry. With the rainy season emerging, there are additional concerns about weather protection and drainage. Nevertheless, the substructural work inched forward with big digs, long tubes of steel linings welded end to end, gnarly steel cages, and finally concrete.

Recap of Weeks 2- 4 (The First Pour)

During the first weeks of foundation work, the crew mobilized their equipment and laid out all the positions for the piers. They began by drilling the first four pier holes along the edge of the existing house to support the addition and to underpin the existing foundation. As mentioned previously, our site is basically a sand dune and the loose soil is prone to caving. Getting to the 25+ foot depths required by the soils engineer proved to be arduous.

To reduce the risk of caving, the crew poured the piers in two stages. The initial pour included the five 25+ foot piers and seven 8′ deep deck piers. Photos below show the arrival of the truck and equipment assembled for the first concrete pour.

Most of the time, our site looked like a giant bowl of flour! In the beginning, the excavator scraped the edges of the bowl and pushed the floury dirt around. It felt even more similar to baking when the concrete was finally pumped from the hoses during our first pours. The liquified concrete pouring out of the hose looked like thick whipped cream extruded from a pastry tube, but not as appealing.

Week 5-6
Concrete being pumped from the truck to the pier holes along the side of the house

The foundation crew continued to drill holes, insert steel casings and rebar cages for seven “shallow” deck piers. These piers were drilled approximately 20 feet to bedrock. The sandy soil continued to present challenges, as the soil had no compressive strength and collapsed when drilled. Geo-grout was used to stabilize the openings so drilling could be accomplished more reliably.

It was very humbling to watch as each day’s events unfolded. Every crew member was fully engaged. The video below shows pier holes being drilled by the excavator and a crew member guiding the drill into position while another crew member cleared the sandy soil from the drill. A fourth crew member checked and adjusted the grout in one of the piers.

Messy work! Concrete poured into exterior deck piers required hand removal
before it set!
Week 7 (Pour No. 2)

The final stage of earthworks began. The crew drilled the five remaining 24″ wide holes for the piles that support the addition. The cement truck returned and issued the second installment of concrete.

As in the first pour, the geotechnical engineer, the city building inspector, and the special inspector reviewed and approved the excavation and reinforcing steel before the second concrete pour. Our construction manager choreographed the intricate dance between consultants and contractor.

Concrete being poured into pier holes
Week 8

Once the steel casings were put into place and the holes were drilled, the steel reinforcing cages were guided into place with the excavator.

Steel casings being lowered into openings

You can get a sense of the depth of the opening by the height of the caging, which in some cases were over 30 feet long. In order to lower the cages smoothly along the full depth of the opening and to ensure enough clearance for the concrete to be poured around it, the crew attached rolling spacers in intervals at vertical bars along the edge of each cage.

Daily spot checks from Foreman Felix ensured that the construction manager was on site during this stage of construction.

Foreman Felix from his perch

Coming next….Retaining Your Form