More Good News

Each day seems to bring some more good news. Bernie from Clarke County Plumbing and Tom from Creager Electrical both were on-site this week and have worked on the final details. For Bernie's part, he's been attaching the bathroom fixtures (hanging the toilets on the wall, attaching the bath and shower faucets, etc.). Tom's been completing the circuits for a host of indoor and outdoor lighting and electrical connections. If all goes well, Bernie will finish the plumbing on Thursday, and have a final inspection on Friday. Tom will finish early next week and have a final inspection then. Jeff Gunther from Grove Construction was back on-site today to finish installing the beautiful cedar siding on the West side of the house, and the final trim piece on the East side of the house. Andreas snapped this picture of Jeff before the sun went down, just before Jeff installed the last few pieces.

Jeff installing cedar on the West side of the house.

Meanwhile, Andreas and I have been busy with some tasks of our own. I joined the two pieces of the kitchen counter by the range, using a new Dewalt plate joiner toy (er, I mean tool), and Andreas sanded it and put two coats of Safecoat sealant on it, which we purchased from Amicus Green Building Center. Faceplates have been installed on most of the remaining outlets. The pipes around the hot water heater and the radiant floor system have been insulated. I still have to grout the master shower floor, and seal all of the grout in each of the bathrooms.

North side LED step lights and front door light.

South side LED step lights.

LED step lights into the basement.

Fuzzy picture (low light) of insulated water heater pipes.

Fuzzy picture (low light) of insulated radiant system pipes.

More ELFA in the master closet.

One Step Closer to Toasty Warm

For several days I had intended to take a picture of the radiant system in the basement. We previously posted pics of the pex tubing that's in the floor, which are the veins of the system. but the heart of the system is quite impressive. And it's mostly installed. We purchased the system from Radiantec and they did a fantastic job answering any and all of our questions as we worked with Bernie from Clarke County Plumbing to connect the system. Speaking of Bernie, he claims he's still snowed in, so he didn't show up at all this week to work on our house. Andreas pleaded with him yesterday to come next week - and plan to spend the whole week there.

While the system itself is connected and pressure tested, Bernie hasn't fully installed/connected the Polaris gas water heater. He was supposed to connect the gas line on a previous day, but he deferred that to a future day, and hasn't been back. He also needs to install the expansion tank, a heat trap (as required by Earthcraft for certification) and connect the overflow to the drain pan or sump pump. Today, Washington Gas came to install the meter outside, so as soon as Bernie shows up again, we'll be ready to fire it up and test it out.

Then the other piece that needs to be connected for the radiant system to be operational, is the thermostat controls. Andreas installed all of the thermostats on the walls and now we need Tom the electrician from Creager Electrical to show up to connect the temperature control system (the brain) to the heart so we can control the temperature in each of the five zones.

It will be really wonderful to have heat in the house, since we still have some work to do inside. But I suspect most of our inside work will be complete before Bernie and Tom are able to finish their work.

The outside of the house has been a better situation. Jeff Gunther from Grove Construction and his sidekick Andrew did a wonderful job on the deck, which they finished yesterday afternoon. I'll take some pictures of the final product and post those early next week. Jeff and Andrew need to come back to clean up their work site (which has been in the neighbor's back yard) and Jeff will finish installing the cedar siding that Aaron Holmes's crew never completed. That's scheduled for Saturday, January 2nd since Jeff is taking some well-deserved time off around the holidays. I think the house will look much better from the street once the cedar siding is visible on the Western side of the house.

Deck the Halls

I'm back from Montreal and spent the day working on the house. Evidently, I brought the snow with me. One of my priorities was to inspect the work that Jeff Gunther is doing as he constructs the deck. All I can say is, "wow!" So far, it appears that he's doing a very good job with this, as you can see in the pictures.

We had ordered the finish trim wood so Craig can start next week with the trim carpentry. TW Perry's crew dropped the wood in two stages - the first batch, Jeff carried in for us since Andreas and I both were out of town for work. The second batch they dropped in our neighbor's front yard. Fortunately, it was wrapped in plastic, so the wood didn't get damaged with today's rain and snow, but I felt badly that our neighbors had to have a stack of wood on their front lawn for a day until I could get to the house to carry it inside. Walking through the snowy mud wasn't fun, but the wood needed to be moved inside so it can start to acclimate with the house's temperature and humidity level.

In addition to the deck and the wood delivery, a number of other things happened last week. Bernie the plumber came to bring the rainwater capture fresh water line into the house, but realized when he got there that he was missing an attachment to a tool, so he couldn't drill through the foundation. So he moved on to another project - installing the hot water heater. And we uncovered another problem. Aaron Holmes told us this summer that the radon vent was going to be in the utility closet off the basement bedroom, and he had Bernie set PVC piping for the gas hot water heater vent. As Bernie looked at setting up the hot water heater, it occurred to him that it needed to be vented. Andreas reminded him that he already set the PVC piping for the vent. Nope - what's there is the radon venting. Another unbudgeted item - drilling through the foundation for the hot water heater vent.

So after speaking with the City inspector and learning the details of where the natural gas hot water heater vent pipe can go, Andreas arranged for Bob DeMarr's crew to come out to drill a hole near the hot water heater and another in the utility closet for the rainwater line. Andreas made a point to emphasize the importance of cleaning up after they drill the hole, so the crew did an okay job sweeping up the concrete and removing the concrete core, but they totally messed up our finished basement floors trekking gobs of mud throughout the entire basement. It took a long time today to clean up after them, and I'm still not done.

I checked some small items off the to-do list, but I didn't get as many done as I wanted to. Tomorrow's another day and I hope it'll be more productive.

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.

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.

Friday Progress

A few steps forward, a few steps nowhere. Bernie from Clarke County Plumbing connected both our sump pumps, and removed our temporary sump. Once power is connected to the house, we'll have two sumps running as necessary to ensure the water level stays tame (below the house, that is).

The sump outflow into the drain tile:

A step nowhere was the power connection. Dominion Power talked a good talk about service standards to connect the permanent power, promising an install within three weeks of the order date. We originally were told it would be last week. Then on Monday, we were promised this week, absolutely, the power would be connected. Miss Utility has spray painted all of our neighbors' yards so often that it looks like kids came through marking graffiti! But still no permanent power service. We'll stay on their case - we need the power to be connected on Monday, or we may have to manage new challenges.

That new challenge is the delivery of the rainwater recapture tanks. Three tanks, 1,400 gallons per tank, totaling 4,200 gallons of rainwater. Those, too, were supposed to have been delivered this week, but they didn't make it. We didn't push that at all since Dominion Power's subcontractor has been a no-show.

The folks at ARS continue to do a great job installing the ducting for the TRV. They'll be back on Tuesday and they expect to finish then. The weather hoods for the TRV were supposed to come in today, but...you guessed it...they didn't. We're hoping they'll arrive on Monday, and Bob DeMarr's crew can come out to drill the holes in the TerraBricks for the TRV air inlet and exhaust, as well as the dryer exhaust and fireplace fresh air inlet. Demarr has a core drill which will work perfectly for each cut. Tools are a wonderful thing!

Piedmont Roofing came today and installed the flashing around the East, South, and West side of the house. It looks like they did a nice job, but Aaron will have to inspect it when he's back on our project next week. We don't know if Piedmont re-sealed the flashing on the Northern side, which seems to have been allowing water through at the seams.

And we inspected Bartley's work with the concrete floor. Overall, the floor is really cool and it's definitely the contemporary look we're going for. Bartley's crew did a pretty good job with making the floor as smooth as possible. My three complaints are: 1) the shower was poured to the wrong height - it's too low as compared to where the drain was set, and now the water won't go down the drain unless we install tile on the shower floor which will cost us more money and is not the look we want. 2) they tracked mud into the still-wet concrete, so we have a few spots throughout the first floor where one can see mud in the now-dry concrete. The crew knew this was to be our final floor finishing - nothing on top except some soy-based stain. We explained that to them before they poured and insisted they be extremely cautious as to not track any dirt or debris in, or allow any dirt or debris to rise to the top, so it was irresponsible of them to allow this. The good news is the soy-based stain color is espresso brown, so it probably won't be a problem at all. I just can't understand why workers simply ignore such important details. 3) The workers were extremely sloppy and they did not clean up their messes. There are drink containers around the house. But most disturbingly, they dumped concrete all over the place and did not clean it up. I heard Aaron give them very clear instruction, and I heard their acknowledgement understanding the instructions, that they needed to be extremely careful about where any concrete is dumped on the lot. It needed to be dumped on OSB (leftover from the parging project) at the front of the lot. Again, instructions ignored and it's extremely disappointing that Bartley's crew did not clean up after themselves. This weekend, Andreas and I will be out there cleaning up after Bartley's mess once again, then driving the concrete to the dump and paying for it to be recycled by Fairfax County. Question for any sub-contractors reading this - why is it so hard for your colleagues to follow some simple instructions/requests?

You can't see clearly in the picture, but here's the shower poured to the wrong height:

Here's their mess:

And, the moment you've been waiting for, the concrete first floor:

Long Progress Report

Before I head off to San Diego for a quick work trip (27 hours out of town, 12 of which will be at an airport/on an airliner), I wanted to give a brief progress report on construction.

While we remain frustrated that several subcontractors think it's perfectly OK to not show up when they say they'll be there, there are some bright spots:

Tim Griffin from ARS has been working with us to calculate the HVAC loads for the house and determine the ducting requirements. An energy efficient, air sealed house is a lot different to work with than conventional construction. And our passive solar design adds another twist. Tim has experience with green construction and the Earthcraft Virginia program. And our budget constraints offered another challenge. Tim designed a system and lined up a crew - they're scheduled to start the duct installation on Monday.

The last four days were absolutely exhausting. Andreas had three off-days in a row, so I took some vacation days from work and also spent Wednesday morning on the project. We worked our tails off on the house. I wish everyone we're paying to assist and manage this construction project were doing the same.

Wednesday morning, Aaron and I installed the fan and the fresh air intake system to the fireplace and set that in place.

Starting on Thursday, I spent a full 10 hours on my hands and knees vacuuming the first floor of the house with the shop vac so there would be no dust and debris to contaminate the concrete floor when it's poured next week. Despite multiple requests for workers to clean their shoes before entering, most folks just kept walking in, tracking more dirt for me to vacuum up. I don't mean to sound so negative. But, really, how difficult is it to clean off your shoes before walking into the house, especially after you've been specifically asked to, with the reason for the request explained to you?

While I was inside vacuuming, Andreas was completing numerous projects, including digging a trench to install the drain tile so the sump pump outflow will run under our intended garden area into the stream at the back of the lot. It looks great and is ready for Bernie to install the two cast iron sump pumps next week.

Elmer sent a crew on Thursday evening to install the nailer strips along the exterior walls (the TerraBrick walls). This was to fix mistakes Aaron had made when he cut and installed nailer strips some time ago, but they were of varying heights, so they all had to be removed and trashed. One of the considerations when building with a solid exterior is how to place electrical outlets along those walls. Ours will be centered in a baseboard. The size of the nailer strip in our house is extremely important, as the electrical boxes are screwed into that, and it also is the nailer strip for the baseboards. It needed to be a specific height so that the 1.5" of concrete would not come into the electrical boxes and so the electrical outlets would be a consistent height throughout the baseboards. It was good to get that corrected, since we're hoping that Bartley will be able to come on Wednesday to pour the concrete floor on the main level of the house.

After months and months attempting to get Washington Gas to install service at our house, their subcontractors came on Thursday early afternoon to do the street cut. First thing Friday they were back to trench on the lot and bring the gas line to the back of the house. It was only after I made a phone call to an executive at Washington Gas & Light Holdings that we saw any action. That's all water under the bridge now, but here's a special thanks to WGL Holdings' Marcellous Frye for getting the right people on the job for us.

Piedmont Roofing's crew was supposed to come on Thursday, but they ran over on another project, so they were to be on our project early Friday morning. Mid-afternoon Friday, they finally showed up. But they were not prepared to do what Aaron said he asked them to do. So they installed the roof boots on the plumbing and radon vent and promised to come back on Saturday. They didn't show up this morning. They had several hours of work time before the rain, so it's disappointing they were no-shows.

Tom (the electrician) came on Friday morning and finished everything he needed to for the electrical rough-in inspection. Andreas scheduled that for 9am on Monday.

Accurate Insulation was scheduled to come Friday morning to install the rain gutters. Only one person showed up. He looked at our house and said he couldn't do it himself, so he'd have to get help and come back on Saturday. He said he'd be at our lot by 8am. We showed up at 8:10 and he was there, with a co-worker, only to inform us that the job was COD. Aaron never sent us a contract and most vendors accept payment afterwards. So I drove home to get the checkbook and was back on-site an hour later only to learn that the crew didn't have screws long enough to attach the downspouts through the EIFS and into the concrete columns. So I drove to Brown's Hardware in Falls Church, but they didn't have any 5" stainless steel screws the Accurate folks requested. I then went to Home Depot. They didn't have any either, so I bought some 4" screws (the longest they had) and some 5" lag bolts. As it turned out, neither of those options worked, but the 4" TapCons I had in my truck (leftover from affixing the extruded foam board to the basement walls) fit the bill. All of that running around was a waste of time. After they left, Andreas and I attached some drain tile to direct the water away from the house. As soon as we were done, the rain started to fall. So I don't have any pictures of the gutter and downspouts yet.

After weeks and weeks and weeks, Quality Window and Door sent a service guy out to repair the sliding glass doors that were difficult to slide, install some weather stripping on a sliding glass door that didn't have some, and fix the loose-fitting locks on two of the swinging exterior doors. This was the third service guy to come out to work on the doors. Well, he got most of it done, but we'll need a fourth visit. He didn't have any weather stripping with him, so he couldn't do that. He fixed the two sliding glass doors. And he fixed one of the two locks. Maybe the fourth time will be the charm and someone can bring weather stripping and properly fix that remaining jiggly lock problem. How difficult is this...really?

Loudoun Stairs supposedly was going to come by on Friday to measure for the staircase to the basement and also bring some photos of what the staircase would look like. But they didn't show up. Can anyone recommend a good (but affordable) stair company for some basic stairs into the basement?

Andreas and I installed the pex tubing on the first floor this afternoon (Saturday). We didn't finish until after dark so, again, no photos. Clearly we were focused on getting the job done and not on documenting that for the blog. Sorry folks. We'll snaps some pics later.

While I'm on a flight to the West Coast tomorrow, Andreas plans to clean the basement floor so that can dry and allow us to test some sample coloring for the concrete floor stain when I'm back on the project Tuesday evening. There's a lot more on the schedule for next week, but I guess it will get done only if the subcontractors show up. These days, I'm not holding my breath for that! And please don't ask me about the clerestory windows.

Parging's Complete, Plumbing Rough-ins Complete

I'm a day late in posting this - I had trouble with my Internet connection last night after I uploaded the post on the mulch. Elmer's crew completed the cement parging of the interior walls yesterday.

The crew helped our construction manager, Aaron, place the fireplace in its spot in the living room. Unfortunately, when they uncrated the fireplace, they noticed that some of the stones that run along the base of the fireplace were cracked and others were chipped. I guess that's understandable, considering the fireplace was shipped all the way from Belgium. (Don't talk to me about that carbon footprint - actually, it's an exceptionally efficient fireplace that can heat our entire first floor with just a few logs.)

Our plumber, Bernie with Clarke County Plumbing, installed the rough-ins for the basement bathroom and ran the lines for the sump pumps.

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!