Deconstruction

Seasons Services sent a crew out yesterday to remove some of the foam board and EIFS around the house. This is where the 2"x12" pressure treated deck ledger board will be connected to the house with Hilti epoxy bolts.

You might be wondering why this wasn't done before the EIFS was installed, right? So were we, but Aaron from Cornerstone told us we could install the ledger board on top of the EIFS. Wrong again! The code doesn't allow that; the ledger board has to flat up against the concrete foundation and then bolted into that.

Seasons Services removed the extruded foam board along three sides of the house and waterproofed the cut area. Jeff Gunther, who will be building the deck for us, will start installing the ledger board this week. After the ledger board is up, Seasons Services will come back to flash around the ledger board and add new foam board and stucco in any gap that's remaining above the ledger board.

If the weather holds out and it doesn't rain, Bernie with Clarke County Plumbing is scheduled to come in the morning to bring the rainwater tank pipe through the house. Then we can schedule final grading, which will be a most wonderful day!

I'm off to Montreal for work for the week, so I won't be able to blog, but Andreas might provide some updates as time permits.

Shopping Spree

I'm back from my Association's annual meeting & convention, which was very successful. The weeks leading up to the Convention were busier than usual, so I wasn't able to post to the blog. Since I returned last Friday, I've been catching up on work, and working on the Erdhaus.

Shopping for fixtures for the house has been a high priority and a nice diversion from all the work we have yet to do. We ordered tile for the bathrooms and bought LED lights at Amicus Green Building Center in Kensington, MD. The master bathroom will have porcelain tile (12" x 24" horizontal) dark grey tile for the shower walls, and 1" x 1" black (color=carbon) porcelain tile for the shower floor. We selected 18" x 18" ceramic tile for the guest bathrooms. The upstairs color is cocoa and the downstairs color is a light tan. It's kind of funny - Andreas said I could pick the tile colors for the guest bathrooms, as long as I didn't pick tan or brown. As it turns out, we picked the tile colors together, and the ones we liked best were tan and brown. The LED lights were on close-out. Perm lighting is the manufacturer and they were acquired by another company. So the discontinued model was being offered by Amicus for a great price ($70 per 6" recessed light). Obviously they are energy efficient.

From YLighting, we ordered three ceiling fans - one for the living room, one for the guest bedroom, and one for the master bedroom. The ceiling fans are the Velo line by Modern Fan Company.


Tom, the electrician, is scheduled to start installing the interior light fixtures next week. We're holding off on exterior installations until the deck is built.

Another selection we have made is for the walkway to the house. Maryann from Terra Landcaping brought over some permeable pavers and marked out with orange marking paint where the walkway will be. While we have the pavers for the walkway, we're electing to go with a simple gravel driveway/parking area (until I win the lottery and can afford to put permeable pavers there instead).

In addition to having fun shopping, we've been working hard on the projects that we're responsible for. Andreas posted photos of the stained concrete floor. We cleared out the items that were in the great room, cleaned the floor there, and put two coats of stain in the great room. Well, Andreas did that and I helped a bit with the first coat of the soy-based stain. Andreas did the first coat of soy-based sealer on the floor today. The sealer will soak in and then we'll put a second coat on and allow it to dry overnight.


The floors look like a marble or granite counter top. The concrete soaks in the stain differently, so it gives texture and variations in color. The Acri-Soy stain and sealer also came from Amicus Green Building Center.

I took yesterday off from work to paint and my goal was to finish all the painting on the main level of the house. It took a bit of time to get set up, and I realized quickly that I first needed to get the shop vac out to clean up a lot of drywall dust that was in the clerestory area. Then it became clear to me that in order for the paint to look high quality, I needed to do a second coat of primer on the walls before applying the final coat of paint. So I applied the primer in the guest bedroom, guest bathroom, and guest hallway and I put the final coat of paint on the walls in the guest bedroom and hallway. I had finished the great room walls and the pantry last week (right after returning home from our Convention) so almost all the paining (oops, I meant to type painting) on the West side of the house is done (just the guest bathroom to finish). Then I can do the second coat of primer and then paint in the master bedroom, closet, and bathroom. I should be able to finish that this Saturday.

There were a lot of interruptions yesterday, which were welcome (painting gets old after a bit, so it's nice to have a break every now and then). Several people came by to look at various projects so they can prepare quotes for us. Another possible subcontractor called to set a time to look at connecting the radiant floor heating system. Lowes was supposed to deliver our appliances, but I called the night before to reschedule for some time in November since the lot is a mud pit. Even though they called later in the evening to confirm that the delivery was delayed, I got a call from the delivery folks stating my delivery was next on their list and they'd be at the house in 30-60 minutes. Oops. I explained the situation and they apologized, so it was a non-issue.

After Andreas finished his meetings at work yesterday, he came to the house and we installed some drywall on the basement ceiling together. We forgot to ask the drywall subcontractor to do a section of the ceiling at the stair landing and the hallway into the downstairs bedroom area. It took a few cuts of drywall and we installed the two sections together. I'll work on taping/mudding/sanding the drywall in the coming days.

While the inside is taking shape, we're hoping the weather will cooperate a bit so we can re-focus on the outside of the house. We started digging more trenches to finish the rainwater storage tank connections. Two trenches for overflow pipes and one trench to bring the water from the tanks to the house. (We've double-plumbed the toilets and hose bibs so they can run City water or rainwater.) Now if we ever again have a period of time without rain so the ground can dry out, we can finish the trenching, get the tanks connected, and then Bob DeMarr's crew can do the final grading.

Once the final grading is done, the subcontractors will install the rest of the cedar siding on the South and West sides of the house. Maryann's crew then can install the permeable paver walkways and we can lay truck loads of mulch over the clay soil to help stabilize the soil and make the lot look much, much nicer than it currently does. And then there's decking to be built, but that's a blog posting of its own - another expensive disaster we're trying to mitigate, compliments of Aaron/Cornerstone Building Services.

Each day's accomplishments brings us a step closer to moving in the house. It's important to recognize how far we've come, since it's easy to see how far we have yet to go.

Update at Last!

Many, many thanks to Mom and Bill for coming two weekends in a row to help out with home construction projects. It's been a busy time since I last blogged, and most of our effort on the house was cleaning up some errors Aaron Holmes (from Cornerstone Building Services) and crews he hired had made. There's still more of that to address, but we're making progress there. The rest of the time was spent moving various projects forward. Much of what we did is barely noticeable, but are important details.

Here's some of what we accomplished:

- Carried 165 sheets of drywall into the house, that 84 Lumber delivered in the yard.

- Measured and ordered paperless drywall for the bathrooms, as required by EarthCraft for the top-level certification (Aaron ordered greenboard, which is not permitted under the EarthCraft certification program top-tier)

- Met with two drywall subcontractors to obtain quotes for installation.

- Prepared PVC pipe for rainwater recapture tanks.

- Corrected framing mistakes (e.g., changed framing so the range hood exhaust can be centered on the wall the way it was supposed to be).

- Installed new framing around the TRV ducting and return air grill ducting in the guest bathroom and the master closet.

- Corrected the range hood vent ducting so it is now centered on the kitchen wall.

- ARS installed the fresh air ducting to the TRV and insulated the ducting in accordance with EarthCraft requirements.

- Nailed in electrical boxes in three areas where Tom from Creager Electrical left wires hanging for future electrical components.

- Mixed American Clay Loma and Porcelina plaster in buckets.

- Photographed all of the framing, plumbing, and electrical wires and noted measurements for each of these so that we know where they are hiding in the walls once the drywall is installed.

- Ordered copper-to-pex fittings to connect the pex tubing with the radiant floor heating system.

- Stained the cedar trim boards TW Perry delivered, which is for the house siding. (Aaron had not specified enough cedar when he gave us the requirements to order more, so the siding work has been on hold until all of the cedar come in. This was the first of three kinds of cedar we ordered again through TW Perry.)

In addition to helping with these projects, Mom and Bill brought us a wonderful lunch and homemade shoo-fly pie for Saturday, and fresh eggs and bacon from Pennsylvania Dutch country for breakfast on Sunday.

Sorry, no photos this posting.

Installing Rain Water Tanks

You might have seen the cute, little rain barrels that one can make from wine casks or plastic drums. Most hardware stores, and all green building centers, have these in stock so you can capture rain water from your gutter/downspout and use it for watering plants, etc. While those are good for existing homes, that's child's play compared to our new rain water capture system. We have three tanks that hold 1,400 gallons each. DeMarr's crew was on site to dig the ditch in the front of the house; the tanks will live under ground. They've been filling the tanks partially with water as they've backfilled the ditch. Bernie from Clarke County Plumbing will be on-site Friday to connect the PVC pipe to bring the rainwater to the tanks, and also to connect the pump system Andreas drove 8 hours roundtrip to Salem, VA to pick up so it would be here on time (another failure on our construction manager's part with poor planning). More to come on this as the tanks are connected, but here are some photos of the tanks in the ground.

The Economy Has Recovered!

Based on the lines at every store this weekend, and the amount of money we spent on the house, I think we can officially declare that the recession in the U.S. ended as of September 7, 2009.

If only that were true....

Over the past few months, we had shopped around for a while at various retailers for appliances. Andreas's boss, Tim, suggested we look at Lowes, since he found them to have the best prices overall. We had a good sense of what the appliances for our house would cost, and then, as it turned out, Lowes had a 20% off all Energy Star appliances sale this past weekend. Ka-ching! It was great. Each appliance we could buy with an Energy Star rating has now been purchased: Washing machine; dishwasher; refrigerator. The dryer and the slide-in range are not available as Energy Star approved. Except in Winter months, we likely won't use the dryer that often anyway, as a clothes line in the backyard will dry the clothes and add a fresh smell that will remind me of home when I was growing up. The range was our splurge - an Electrolux with great features. Our refrigerator/freezer (with the freezer drawer on the bottom) is Samsung. The washing machine, dryer, and dishwasher all are Bosch.

Now it's time to brag and talk bucks. Or savings of bucks, to be more precise. Andreas and I picked out an efficient Bosch washing machine and dryer. We were excited about the quality, but not thrilled with the price. The washing machine alone cost $1,098. That's more than I had ever spent before on an appliance in my entire life. But it was really quality, and really efficient. While we were waiting our turn for assistance, we wandered the showroom floor and came across three floor model Bosch washers - the exact same model as we picked out - marked down several times. All had a few scratches on them, but they still were brand-new, and everything seemed in order. We wondered why these floor models were so cheap. When a sales rep (Zony was his name) was available, we asked him why it was marked down so much. He said people usually don't want to buy them when they learn that they have to buy an $1,100 dryer to go with it. But since we already planned to buy that dryer, this was quite a deal for us. Zony helped us with all of our other appliance questions and the order, then it came time to buy the floor model Bosch washer. He needed an override for the discounted price, so he asked his manager to enter that. While asking his manager for the code, Zony asked him to give us an even greater discount on the washing machine, to which he agreed. Are you sitting down? The $1098 washing machine cost $200. We bought an extended warranty....just in case.

While our appliance brands don't all match, we're excited about the quality we got - best in class (well, best within our budget) for each appliance type. The only appliance left to buy is the range hood, which we'll order tomorrow. We've already picked it out.

While we were on a shopping roll this weekend, we decided to go to IKEA to get our kitchen cabinets. We will have only base cabinets, not upper cabinets. The cabinets we selected are very warm, yet contemporary in style. Fortunately, IKEA had everything in stock, so we took our new cabinets with us. They're ready for assembly! People who like to dismiss the thought of IKEA cabinets either are a bit uppity about name brands, or they don't know the significant increase in IKEA kitchen cabinet product quality over the past several years. My father and I made the cabinets in the kitchen in my condo, and they're beautiful. The IKEA cabinets look almost as good, but for a lot less money.

On a completely separate note, I saw yesterday the work of the siding crew and I am glad that Aaron fired them. Again, and again, and again, I emphasized to Aaron how important it was that his siding crew nailed every board of cedar in a straight, vertical line. I even sent photographs to of other buildings to show exactly what I meant. However, his crew's nailing, which does not show up on the photo we posted the other day, looks horrific! It's like they were on drugs and zig-zagged everywhere with the nail gun. I think all of the siding needs to come off and Aaron will have to replace any boards that are damaged. He had clear instructions, and in writing, so it's his responsibility to make it right.

Inspection vs. Expectation

There's common advice that folks share when talking about building a house -- it's what you inspect, not what you expect. One can provide contractors with detailed explanations of homeowner expectations on design, quality, etc., but trusting that will be done just does not cut it in the construction industry -- there's only one thing that will, and that's inspection. It's disappointing that many subcontractors cut corners. Perhaps it's a lack of training, lack of skill, lack of supervision, or all of the above. But there are too many horror stories related to construction that only strong supervision by the owner(s) and inspection of worked performed will ensure quality construction meeting the design intent. We faced that issue twice this week. First with the new clerestory window installation and then with the deck post installation. Our construction manager, Aaron, was the subcontractor for each of these tasks and his crew just failed to get it right the first time. The end result is they're doing the work over, which is taking more time, costing Aaron more money, and adding unnecessary stress and frustration (for us, for Aaron, and for his crew that's doing the work over again). So the clerestory window saga continues. One of the selling points for using Quality Window & Door was that they would send a technical rep to oversee all window and door installations if you bought windows through them. That's included in the price. This is another area where they failed. When the original windows and doors were installed, the tech was there for only part of the day. This time, they couldn't find a rep who was available, so the sales guy who royally screwed up our clerestory window order came instead. He doesn't seem to know anything about window installation either. The fact is the five windows that were installed on Tuesday were put in wrong, under his and Aaron's supervision. The workers did not follow the WeatherShield installation instructions, nor the EarthCraft House program's technical guidelines. Andreas caught the error. Had he not inspected their work, all of the windows would have been installed incorrectly. There were a whole host of problems, and now the windows will have to be removed. One primary concern was that there was no house wrap (e.g., Tyvek) used for the window installation and the caulking was wrong. Had this not been inspected, the problems would rear their ugly heads years down the road. Once again, Chris Conway, our EarthCraft Technical Advisor saved the day as he confirmed that what Andreas described was incorrect and he walked Andreas through the correct installation process. (This is probably the 40th or 50th time we've called him with technical questions related to green construction and he has been unbelievably helpful and patient with us each and every time. He's amazingly knowledgeable and helpful!) We spent Wednesday morning on-site so Andreas could supervise the window installation to ensure the crew understood the EarthCraft technical guidelines and I could supervise the cedar siding installation that had been scheduled. I was leaving early Thursday morning for a work trip to Aspen, CO so this was the only opportunity to meet with the siding crew. As it turned out, the siding crew was unable to do any siding installation since they had to help the window crew install the windows. By the end of Wednesday evening, about 15 of the windows were correctly installed, with 7 left to go (plus the work of removing the incorrectly-installed windows.) The second inspection came quite by accident. While we were on-site, we noticed that one of the deck posts on the North side of the house was leaning. Since Dominion Power's subcontractors were trenching there, we thought they might had bumped it with their Bobcat. It turns out they didn't, but the posts were not installed correctly. There are concrete deck piers. The 6"x6" pressure treated posts must sit directly on the deck piers. Apparently, Aaron's crew decided they would set one short piece of post on the concrete pier, and then set another short piece post on top of that - instead of one proper length deck post. Apparently someone leaned on the first deck post on the North side of the house, it shifted in the soft clay soil, and that's when we pulled it out to inspect what was causing it to lean. That was very disconcerting so we checked the next one -- it was also wrong, with two shorter pieces stacked on top of one another. We brought this to Aaron's attention, checked the third one, and that one was fine. Now, we need to pull out each and every deck post to find any more that might have been installed incorrectly, and Aaron will need to replace those. Again, more stress and frustration (and expense to Aaron) that would not be an issue had Aaron been on-site supervising his crew and/or his crew had been properly trained and/or skilled to perform this job right the first time. Yes, Aaron's accepting the responsibility for these mistakes and we hope these are isolated instances and no future situations like this will arise. If they do, we'll know, as we'll be inspecting all of the work that's done. Speaking of inspections, the City inspected our framing and mechanical systems yesterday afternoon and both passed. Southland Insulators will be on-site Friday morning to spray foam insulation in the roof/ceiling area and around the basement upper walls (in the joist areas at the outside perimeter of the house.) Then we can schedule a close-in inspection and start installing drywall!

The new clerestory windows that have been installed look really great (again, no photos of those, since it was dusk when we got to the lot after going to our offices to work during the afternoon and early evening.) You can get the idea, though, from the picture taken inside looking out in the "incorrect installation" series below. (The window with the cardboard is the one that was broken upon delivery from WeatherShield to Quality Window & Door.)

Incorrect Installation:





Corrected Installation:




Leaning Deck Post:

100th Blog Post

This marks our 100th post. And I'm happy to report there's been some more progress. In the past couple of days, our recycling dumpster was hauled away. We filled two dumpsters during the construction, which is less than 1/2 what typical construction sends to the landfill. And many of the items placed in our dumpster will be recycled instead of dumped.

Bob Demarr's crew spent about 7 hours fixing the problems with the rough grading caused by Bartley Corp's team. Bartley's job foreman admitted to Andreas that they really don't do grading work - they don't have the right equipment or labor. That showed with the mess they created. It took Andreas more than 30 hours to dig out tree protection fencing Bartley ran over with a machine and dumped dirt on top of. I spent another 10 hours uncovering the Holly Tree roots they graded over, even though the root protection zone is clearly marked on the grading plan. Alas, we're now on the right path with grading. Demarr's crew hauled away a few truck loads of dirt today, leaving the lot looking much better than it has the past six months!

Inside, Bernie from Clarke County Plumbing, continued work on the rough-in plumbing. He put the vent pipes through the roof (now Piedmont Roofing will come back to seal that all up) and worked on the basement bathroom. Ferguson delivered the tub, toilet wall carrier and shower faucet rough-in and Bernie will install that soon. He also drilled through the EIFS to prepare for the outdoor shower piping, the hose bibs, and the sump pump piping. Unfortunately, he drilled the sump pump holes too high - the sump pump pipes were supposed to come out beneath the deck - so we'll have to work with Bernie to get that resolved.

Also inside, Aaron laid the pex tubing for the bathroom radiant floor heating. I want the shower floor to be as toasty warm as the rest of the bathroom floor, so that had to be laid today so a first layer of concrete can go over the pex tubing in the shower tomorrow. Bernie can then protect the shower floor properly with the rubber membrane and when the concrete floor is poured, it will work out perfectly.

Elmer's crew started work today on the parging. They spent the day applying a metal lathe around the doors and windows. They'll finish that tomorrow then apply the thin layer of cement to the walls and round out the edges by the doors and windows. After that cures, I can apply the American Clay Earth Plaster over the cement parging.

Jay with Quality Window & Door hasn't provided the exact date yet for the corrected clerestory windows to be delivered - hopefully that will be in the early part of next week so the cedar siding can go on Thursday morning.

Progress!

While I was out of town, a lot of things happened at the house. I need to get out of town more often, so progress continues!

Bob DeMarr and his team did the street cut and trenching to the house, as you saw in the photos from the other day. Later in the week they drilled through the 12" thick concrete foundation to bring the water and sewer lines through into the house. Meanwhile, Bernie from Clarke County Plumbing was on-site working on the rough-ins for all of the plumbing - bathrooms, kitchen, laundry, etc. Southland Insulators came back to finish the air sealing in the first floor. And Bartley's crew came back to re-do the deck piers they excavated and poured way back in February (the ones that collapsed when the excavation for the basement began). So we now have footers for the deck framing that will begin on Monday. Also this week, Bernie will continue with the rough-in plumbing to connect the sewer/water lines and the sump pumps; Elmer will be on-site to do the parging over the interior TerraBrick walls (except the pantry, which we're leaving as bricks to show them off), and Aaron will continue with his to-do list of items he needs to follow-through on, such as correcting the height of the baseboard outlets, installing the fireplace chimney and 6" duct for the range hood, etc. We're close to plumbing and electrical rough-in inspection time, which is very exciting.

The latest word on the corrected clerestory windows is they should be here early next week. Once that's done, we'd like to move quickly on finishing the exterior, laying the radiant floor pex tubing, and pouring the concrete first floor so we can then close-in the walls with drywall. It now looks like we're aiming for a mid-October move-in. Stay tuned!

EIFS, Act 5

Andreas is out of town for work and I'm back from my trips, so it's my turn to blog again. I hope you have an enjoyable Independence Day holiday today.

The crew from Seasons Services finished up the EIFS installation on the Southern side of the house on Friday morning. They work quickly! They've taken down almost all of their scaffolding as well. And they've caulked around all of the doors and windows so they're sealed properly from the exterior. Now that the basement doors arrived and Aaron has installed those, they also started the EIFS in the areaway. Since the EIFS installation is a process, they'll come back a couple of times to finish that section. There are some other minor details they need to take care of - such as completing the work around the step light electrical boxes and cleaning up the site. But we've been really pleased with Seasons Services' work on the EIFS installation. They're quick, professional, on the job when they say they're going to be there, and the quality of their work is very high. Here are some pictures of the Southern side:

Wrong Windows Removed, More Flooding

At long last, our construction manager, Aaron with Cornerstone Building Services, finally had a framing crew out to remove the wrong clerestory windows and prepare the framing for the new, correct, windows. Well, the day they finally came to work it rained (they were supposed to start last Friday, then delayed to Monday, then delayed to Tuesday, then delayed to....you get the point - they finally came on Thursday to work). And it poured. And there was a huge thunderstorm. The lot was a complete mud pit (as you see in another post) and that made it very challenging work for the crew. But all of the windows appear to have been successfully and safely removed. However, during the process, they clearly were not being careful enough, as there was some damage to one of our sliding doors on the south side. The picture isn't clear, but there's a dent in the metal frame. Ugh. 

To add insult to injury, during our early morning call with Aaron, Andreas gave explicit instructions that the crew needed to be 100% certain that the sump pump was plugged in before they left. You guessed it - they didn't ensure it was plugged in. I know it was plugged in last time we left the lot, so someone from that crew must have unplugged it (either intentionally or unintentionally does not matter as they had instructions to ensure it was plugged in). So the basement completely flooded again. Hours and hours of cleaning up dirt from the last flood was completely wasted by simple laziness, idiocy, or both. I was not happy when I discovered that on Thursday evening and I'm still unhappy about it. The last picture below shows the water draining from the basement several minutes after I plugged the sump pump back in.

Welcome Back Aaron

Our contractor, Aaron Holmes, was on vacation over the past week. We'll be glad to have him back so construction picks up pace. Last week we expected the plumber to come to start rough-in plumbing work. No show. The good folks at Bartley were going to do the final grading. Rain prevented that. Andreas was able to caulk the interior edge of the sill plate, which sits on the foundation, to prevent air flow. We cleaned around the house/lot as well. Other than that and the shopping mentioned below, it seems like there isn't any noticeable progress, but we certainly worked on various aspects of the house each day. 

With Aaron back in town, hopefully he brings good weather with him since Bartley will be on-site Wednesday morning to start the final grading. We also will sit down with Aaron to review the next details of the construction, to ensure everyone's on the same page, and we will go through the EarthCraft Virginia green building worksheet to verify that we're meeting the required sections and earning points as we planned at our first meeting with Chris Conway, our EarthCraft Technical Advisor. It's better to spend time reviewing the standard/requirements on a regular basis than to miss something and not get certified as a result. Details, details, details!

We enjoyed meeting a few folks on the lot in the past week as well. Jes and Jody are using the same house designer for a planned renovation of their home in Arlington, so we showed them our house and exchanged war stories. Chris Conway came by yesterday morning with some folks from the Environmental Protection Agency who are involved in developing the EPA's new green home program focusing on indoor air quality. It was great to get their perspective on the house. 

Shielded from the Weather

It's amazing what can happen in one day! Several key projects were completed (or mostly completed) yesterday. 

The crew from Piedmont Roofing installed the felt underlayment for the standing seam metal roof. So if the rain comes, as forecast, the house should stay nice and dry!

Quality Window & Door delivered all of our....you guessed it....our WeatherShield windows and doors. And there are a lot of them!  All of the windows, with the exception of the basement windows, have been installed. The basement windows will be installed on Monday morning. We still need to buy a double door for the basement area way entrance. We looked last weekend at Community Forklift, but they didn't have any double doors in their inventory. I'll try to get to Habitat for Humanity's ReStore in Alexandria this weekend to see if I have better luck there.

The framing crew also built out most of the interior walls as well. I am a little concerned about some of the door/entrances that are supposed to be framed for pocket doors, since I don't see how a pocket door could possibly work the way they framed it. And the closet along the North wall of the master bedroom is so narrow, I don't think a suit could hang in there. So that's not good at all. I'll be heading out to the house this morning with a suit (on a hanger) to try to closet on for size, so to speak.  I couldn't possibly live with a closet like that as it would be a daily reminder of one of the worst hotel stays I've had recently - the Radisson Hotel in the Stapleton section of Denver -- which had a closet built the same way. All my clothes had to be pushed back on an angle in order to close the closet door, resulting in wrinkles. (I'm not that tightly wound -- the closet wasn't what made the hotel so terrible, there were a host of other negative things, but I've digressed from the point of this post, so I'll stop my hotel complaining now.) Our contractor, Aaron, will be on-site Monday morning with the framing crew to ensure any mistakes or problems are promptly corrected.

Finally, the folks who will be doing the EIFS on the exterior of the house supposedly dropped of a sample of a smoother, lighter grey finishing since the one they did for the Renovation Nation filming is a bit more course and dark than we'd like. I couldn't find the sample and didn't want to get in the way of the framers, so I didn't poke around too much looking for it. I'll see it today.

Shaken, Not Stirred

Bond. Bond Beam's the name. This week marked a significant milestone for the house construction project. The bond beam forms were completed, they passed inspection, and the concrete was delivered/poured. Now the Post & Beam construction of the house, which is the code section that the plans were approved under, is complete. We have concrete columns, a continuous bond beam across the top, and the structure is in place to support the roof. The TerraBricks technically are in-fill for the walls, although they certainly are strong enough to have been a structural component of the house. Obtaining approval for the TerraBricks to be structural would have been a significant hassle and expense, which proved unnecessary with the post & beam option.

Now that the bond beam has been poured, the contractor for the CEBs & pouring of the concrete (Willie is the guy's name) just needs to replace some FSC lumber they used and clean up after themselves. Once that's done, we can settle up and put this contractor experience behind us - for good.

Even though we're a few weeks behind schedule, our primary contractor, Aaron from Cornerstone Building Services, thinks much of that time will be made up on the roof installation. I hope he's right - Mother Nature has other plans as it rained all day today and showers are in the forecast for the next five days.

Timeline Until We're Under Roof

I just received an email from our contractor, Aaron Holmes with Cornerstone Building, providing a revised time line to get the house under roof and interior framing completed. I thought I'd share it here:

- Complete stacking of TerraBricks above window and door headers & create Forms for the Bond Beam - this week
- Inspection of Bond Beam by City - Monday morning
- Pour Bond Beam - Monday afternoon or Tuesday morning
- 2 days for bond beam to cure before removing forms
- Framing for Roof & interior first floor - April 30th & May 1st
- WeatherShield Doors & Windows delivered and installed May 1st
- Electrical & Plumbing Rough-ins in first floor - Week of May 4th

As you may recall from the house plan post (see post entitled For Larry M.) there is no second story of the house, so the list above is a substantial amount of work to get the house closed up so interior projects can be initiated. Very exciting! Let's hope everything stays on track!

Saturday, CEB Demonstration

WOW! What a fantastic day! We were hoping some folks from the green community would stop by to observe the manufacture of the TerraBricks/CEBs during our demo that we had scheduled and announced a few weeks prior. We had well over 100 people throughout the course of the three hour demo period, with some arriving early and others still coming after the end of the demo. The weather was spectacular, friends and relatives were able to come by, and my colleague, Scott, and his wife, Laura, brought cupcakes that folks enjoyed.

The folks who attended were a mix of people from within the green community, including Jason from Amicus Green Building Supply in Kensington, MD, some folks who consult and supply "clean energy solutions" and a whole host of consumers - and even a delegation from the Government of Costa Rica - who heard about CEBs and wanted to check out the demonstration as they consider this technology for their home construction.

The demo was a great marketing opportunity for our architect, John Spears, with the Sustainable Design Group, our contractor, Aaron Holmes with Cornerstone Building Services, and the folks at TerraBuilt who leased the Green Machine to us.

It was also great to show off our construction project to my family members who were in town visiting from Pennsylvania.

We'll have some short videos coming soon in another post showing the Green Machine in action and the crew stacking the bricks.

Our Contractor, Aaron Holmes, talking with a demo attendee.

John Morris from TerraBuilt explaining the Green Machine.

A normal miter saw is used to cut the TerraBricks/CEBs.

City of Falls Church green program leaders gather to watch the crew set some of the TerraBricks.

Setting the TerraBricks.

Our friend, Jeff, ready to video the crew set the TerraBricks.

TerraBricks in place - two levels high.