Day 180 - Oh Blogger Where Art Thou?

I can almost hear the bluegrass gospel playing in the background :-)

So it turns out that January really isn't a good month for blogging.  Between the cold weather, lots of work & a ski trip to Colorado, I just couldn't find the time to blog.  Fortunately, it was a great month of construction at the house!  There has been a TON of work accomplished since I wrote the last post.  With so much having gotten done, I'll just break it down for you section by section.

Plumbing

All of the plumbing is roughed in.  Nick from Hoffman Plumbing did a great job.  Here is what our Manabloc looks like along with some random picks of all the PEX tubing.

Looks pretty good!

This is the jungle of tubing/pipes/wires coming out of the mechanical room.

Check out that bundle of water lines heading to the 2nd floor!

Red = Hot.  Blue = Cold.

Vent pipes above the laundry room.

Emily’s tub finally arrived!  It was a bit of an ordeal to get it here, and to be honest until I saw it with my own eyes, I was beginning to think that we might never actually get it.  We ordered the tub online from a website called Homeclick way back on 12/9/13.  They had the cheapest price by over $150.  Needless to say we jumped all over that bargain.  It was a 4 week backorder (with other websites it was a 12 week backorder!).  Well, 4 weeks came & went with no confirmation that our tub had shipped.  We spoke with 3 different very polite (but clueless) customer service people from Homeclick.  One person said the tub had shipped and already been delivered.  A second person told us the tub was still sitting in the warehouse.  A third person told us that the freight company had it and there was nothing more she could do for us.  Ultimately, the tub got delivered safe & sound on 1/22/14 while we were on vacation in Colorado.

Baby blue.  Sky blue.  Powder blue.  Whatever.  They all work!

The alcove tub in the kids bathroom has also been installed.  It's 6ft long & 3 ft deep.  Lots of room for the kids as they grow. 

No quite as fancy as the other tub.

 

HVAC

All the HVAC ductwork is installed.  All of the seams are either sealed with tape or painted with mastic to minimize air leakage (Yep, I just used the work leakage).  The only hiccup with the ductwork occurred after it was installed.  While framing a half wall in our entryway, Al decided to test his aim and shot a few nails through the subfloor and directly into the HVAC duct sitting between the trusses below the wall.  I think it's time for Al to holster that pneumatic nailer!

Say hello to the wall that caused holes to be shot into the ductwork!

Temporary electric heater.

A little bit of everything in the basement ceiling.

Electric

It just so happened that the week we left to ski in Colorado was the week Brian from Kummet Electric was wiring our house.  I was very glad that I had gone over the blueprint with Brian before we left.  There were still had a few questions that came up while we away, but they were easily handled over the phone.  Brian did an awesome job wiring the house.  Running the electrical in a SIPs home is probably the single biggest challenge compared to a traditionally framed house.  All of the SIPs have electric chases predrilled into them.  Extreme Panel marks these chases every few feet with red lines on the OSB.  Unfortunately, sometimes these red lines get covered up by tape of framing from the interior walls.  That meant Brian had to occasionally take his best guess to find the chases.  Other SIP manufacturers mark their chases all the way across the panel with a continuous line to avoid that problem.  Once the chase has been identified, the electrical wires need to be fished through the chases using a stiff metal wire.  In order to connect panels with each other, Brian had a ~6 ft long drill bit that he used.  Yes, I had just a little drill bit envy.

External recessed lighting

Under the front porch

Kind of looks like a horses tail

The wall below has been reframed 3 times so far.  First they forgot to frame-in an opening for the pantry door.  Second, we had to reframe the door to make room for the pantry shelves.  Unfortunately, we had to reframe the doorway again to make room for the electrical box!  Hopefully the 3^rd time is the charm, and the wall can stay put!

The most impressive thing about the electrical work however was how Brian recessed electrical outlets into the wooden beams in the ceiling.  Some of the beams were over 20 ft in the air!

Click on the pic to check out the box way up in the beam!

Master bedroom ceiling

My brother-in-law, Chad is an electrician.  He came out after we got back from Colorado and helped me install the speaker wire for the home theater system in the the family room & in the basement.  Thanks to Chad, we got all of the wires pulled and stapled into place in just a few hours.  With me in charge, it would have taken at least 2 full days!  Thanks Chad!

dChad, Lyssa & Harry taking a lunch break

Spray Foam

After the electric was inspected on 1/29/14, Tri County Foam Insulation out of Carlos came on 1/30/14 spray foamed all of the areas that didn't have SIPs.  The main area that required spray foam was the garage ceiling.  This was to finish insulating the bonus room above the garage and provide a vapor barrier to prevent exhaust fumes from seeping into the bonus room.  we also had all of the garage door headers, the rim joist around the basement & a cantilevered area in the basement ceiling.  Initially we accepted a bid from a different spray foam company, but after they came to the house and remeasured the job, their quote almost doubled!  Tri County Foam honored their original estimate which ended up being several hundred dollars cheaper than the competition.  They did an excellent job.  They were quick, professional and cleaned up after themselves before they left.  Emily took some great action shots of the foam being applied!

Beep...Beep...Beep...

Mmm...Self expanding, sprayable petroleum products... ;-)

I was hoping they would use purple foam, so I could call this pic "Purple Haze"

Finished Garage Ceiling

Foam close-up

 Dry Wall

PJW Drywall began installing the Sheetrock on 1/30/14 at the same time the spray foam was being applied.  So far the upper stair well and all of the bedroom ceilings are done.  You can really start to see the rooms taking shape!  On the down side, pretty soon I will no longer be able to walk through my walls!  I would like to take a moment to let you know that my sheet rock installer rolls very high class.  Since he arrived on the jobsite a microwave, a can of Maxwell House coffee & an actual ceramic coffee mug magically showed up!  It's like some kind of exclusive, member's only coffee house inside my very own laundry room.  I wonder if he takes call ahead orders?

Decaf Iced Carmel Latte with Extra Whip anyone?

General Carpentry Stuff

Lots of little things (& some big things) to report on this front.  All of our windows are officially in!  Exciting, right?  The last window placed was the window in the master bathroom that needed to be reordered.

We had a small section of siding up on the exterior, so we could see what it looked like in person.  Well, were it is:

Lighting isn't great, but it's a "Country Red"

Lots more interior framing has taken place.  Here are some pics of the mud room stairs:

Before

After

Stairs leading above the garage

The fireplace is in!  Sure, it's not much to look at right now, but you should see it under a disco ball!

Well,  that's all the news that's fit to print!  We'll see you later!

Day 146 - Year End Wrap-Up

Every house looks better with windows :-)

As 2013 wraps up, we have about half of the windows installed.  Exterior doors have been ordered & then the housewrap.  While it hasn't been quick process, we are definitely starting to see some major progress.

Every house looks better with my beautiful wife in front of it :-)

Brian has about a week worth of work left to finish the HVAC rough-in.  The duct work is looking good.  No major hang ups.

HVAC ductwork above the laundry room

Similarly Nick has about a week worth of work left to finish the rough-in plumbing.  We decided use a Manabloc system for our plumbing.  It looks something like this:

Viega Manabloc

Instead of the plumbing looking like a tree (with a main trunk throughout the house & branches to each fixture), the Manabloc is a "homerun" system were every fixture has an individual line running from the Manabloc.  The benefits are 3 fold.  1)  Less standing water in the line to clean out before hot water reaches the fixture.  2)  Fewer connections that could leak.  The only connections are at the Manabloc & the fixture.  You also have the ability to shut off each fixture individually directly at the Manabloc.  3)  Better water pressure.  Since each fixture has its own water supply, no more scalding hot shower when someone flushes the toilet!  When they get installed, they remind me a bit of a spider.

In other news, we are finalizing the cap for the chimney chase.  We've been working with Alex Brick & Stone.  Currently we are leaning towards a grey stone cap (which is a bit ironic considering we currently live on GreyStone Golf Course) and a copper cap.  It will look very similar to this.

Well that's all for now.  Have a safe & happy New Year!

Day 141 - Shingles, HVAC & the Drama Known Simply as Windows

I took the entire week of Christmas off for vacation this year (payback for working Thanksgiving, Christmas & New Year's last year!), so I've been really busy at work these past 2 weeks leading up to my time off.  Needless to say, I've been slacking on the blog updates.  There's a lot to get caught up on, so buckle up because here we go!

In a nutshell, we have seen a lot of progress on the house over the past few weeks.  Unfortunately, along with the progress, we've also run into a few more headaches (more on those later).

Shingles

A big milestone last week:  The entire front of the house has shingles! (Just the 3 season porch to go & the entire house will be shingled!)

You can see the furring strips that make the air channel between the SIP panel & the shingles

More snow, but I promise there are shingles under there!

 

HVAC

Brian from Albany Heating has started to rough-in the duct-work for the forced air system.  I'm convinced that when architects/designers draw up a set of house plans, they tend to forget about those pesky little details like indoor plumbing, heating & air conditioning!  Between our house plan and the SIP construction, it became quite a challenge to figure out where to put all of the forced air duct-work.  Ultimately, we stole 20 inches of space from the office closet to run the main air supply trunk from the mechanical room to the 2nd floor.  For the return air, we stole space from Betsy's closet to run the air duct back down to the mechanical room.  Sorry Bets!

Brian buried in duct-work

 Due to the SIP roof, we have no attic space to conceal the duct-work for the 2nd floor air return system.  The solution was to put a lowered ceiling over the laundry room & hallway connecting the kids bedrooms.  This allowed us to tie in all of the air returns for the Heat/AC system & the separate ventilation system.

This maze of ductwork will be hidden above the laundry room

Another reason we chose to use Albany Heating for our HVAC is because Brian is very meticulous about sealing all of his ductwork.  Metal forced air ducts are just plain leaky.  A lot of contractors don't seal the duct seams.  The thought is that any air leaking from the air ducts is still inside the house & helps to heat/cool.  The problem with this is that the system become very inefficient.  You heat/cool the dead spaces inside the walls & inside floor trusses.  You also end up with vents that don't put out any air, and the house develops hot/cold spots.  Brian tapes all of his seams & uses mastic (think plaster of paris) when needed.  Here's a link if you want to geek out about ways to seal HVAC ducts.

 

Ventilation

 If you haven't already noticed, one of our goals is to make this house as energy efficient at possible.  Saving the environment is great, but living in a house that has really low operating costs might just be even better.  The geothermal heat & SIP construction are a big part of this.  Limiting the number of openings in the house (i.e. exhaust fans, plumbing vent pipes, etc) is also important.  That is why we will have no individual bathroom fans that vent to the outside.  Instead we installed a single ventilation system that is completely separate from the HVAC system.

All new homes are required by law to have a heat recovery ventilator (HRV) or energy recovery ventilator (ERV) to bring fresh air into the house while exhausting stale air to the outside.

Most HVAC contractors meet this requirement by fully integrating the HRV into the duct-work for the forced air furnace.  This isn't very efficient however, because you need to constantly run your large furnace fan to circulate fresh air throughout the house.  A more efficient way to ventilate a house is to have a smaller, completely separate set of duct-work that circulates air using a smaller fan.  This is the route we chose.

We purchased our ventilation equipment from a supplier called American Aldes.  We also had a company called Ventilation Advisors help us with designing the ventilation system.  It has individual vent openings in each bathroom.  Each bathroom has a timer switch turns on the central ventilation fan for a set period of time.  This practice has been a fairly common in new home construction for the past 10 year or so. The problem with this type of system is that the bathrooms can be underventilated because the systems try to pull air from all bathrooms at the same time.  Our system is unique in that each vent opening has a motorized damper.  Whenever the timer is turned on in one bathroom, the dampers close in all of the other bathrooms.  This ensures that you have a strong enough airflow to adequately ventilate the bathroom.

Bathroom vent with the motorized damper

 

Windows

I'm pretty sure that windows are the bane of my existence right now.   For starters, our new house has a lot of windows.  78 to be exact (keep that number in mind as this story unfolds).  Great for letting in natural light and providing excellent views from your house.  However,  windows are also very good at causing trouble when it comes to building a house because there are so many ways for things to get messed up.  For starters, when we were finalizing the SIP drawings for the house, the CAD designer messed up on the height of the main floor, so all of the windows were a foot too low.  Fortunately Phil at Centre Lumber caught the mistake & we got it fixed.  Windows got ordered back in September & they have been sitting in my garage since early October.

Hello Windows!

The bad thing about having two months go by with your house exposed the elements & plastic wrap over the window openings is that stuff tends to grow.  What type of stuff?  This type of stuff:

Hello mold!

 Mold is never good.  The silver lining to this issue is that the mold is limited to the untreated areas of cut lumber in between the window rough openings.  All of the factory edges on the SIPs were treated with some type of blue stain that prevents mold.  Treatment options to get rid of the mold include bleaching these areas vs. cutting them out & putting new lumber in between the windows.  Neither option is very appealing.  At the end of the day, another problem came up and made the choice for us...

 One of the benefits of SIP construction is that all window & door rough openings are cut at the factory to the exact measurements provided by the window/door manufactures, so window/door installation is supposed to be very easy.  Excellent idea in theory, but not so much in practice (where communication is often times less that ideal).  Here's what happened:  The Andersen Windows rep worked with the lumber yard to confirm the window schedule (all 78 of them) and the rough opening sizes (1/2 inch wider than the actual window per Andersen's published specs).  The lumber yard then sent the window rough opening measurements to Extreme Panel who cut the window openings into the panels.  So far so good, but here's where things turn ugly.

A few weeks ago Tom test fit one of the windows & noticed that the rough opening was too small (He couldn't even get the sprayfoam insulation straw in between the window & the wall!!!)  It's at this stage in the game that I find out Andersen Windows' published rough openings are on the narrow side for how most contractors install windows.  Tom told me that he typically adds1/4" to the published Andersen rough openings when he hand-frames windows.  I spoke with Jamie, our panel setter, and he typically adds 3/4" to the actual Andersen Window size (and ignores the published rough opening size) when telling Extreme Panel how big to cut the window rough openings in the panels.  Unfortunately, neither Tom nor Jamie were involved in determining the final window rough openings.  And me in my ignorance assumed that published rough opening specs would be just that, the size that the window rough openings that contractors need to install windows correctly.  Silly homeowner!

It's at this point I felt like we were trying to do one of these numbers:

Or perhaps:

Unfortunately for me, trying to resolve this situlation became a big game of "not my fault" with all fingers pointing away from whoever I was talking to at the time.  It was almost like congress trying to find someone to blame for the Obamacare website crashing!  In the end, Tom cut out all of the center posts for the rough openings and put in new ones that were slightly smaller.  All 78 windows worth :-)  Yep, that one stings the construction budget.  On the bright side, it got rid of the mold between the windows!  You see?  It ended up being really easy to decide how to take care of the mold issue.  Just redo all of the window openings!

At this point I'm already smiling really big, but the good news with windows kept on coming.  While out skiing with Harry at Powder Ridge, I got a call from Tom about the window in our master bathroom.  We have a small window in the master shower.  This should have been a fixed casement window that doesn't open.  However, the window got ordered as an awning window that cranks open.  Not ideal.  Open wood window + water = mold/rot/unhappy homeowner!  A replacement fixed casement window has been ordered.  Unfortunately, that just means more time delays & more cost overruns.  I'm hoping that the lumber yard will cover the cost of the window because it should have been ordered as a fixed casement window in the first place, but we'll see.

On the bright side, Tom and the gang were hard at work today & got most of the remaining 78 windows installed.  He told me that the house would be enclosed by New Years.  With the exception of the newly ordered window, I think we might get there!

 Odds & Ends

1. All the plumbing fixtures have arrived (except for 1 tub and the toilets)  and Hoffman Plumbing has started the rough-in work.  The plumbing will be done with PEX tubing instead of copper.  We're going to install the system as a "home run" system if possible.  More on what that entails later.
2. We are having a custom ladder fabricated by Messer Repair.  It will bolt directly on the mudroom wall and go to the loft above the main floor bathroom.
3. I met with Brian Boser, the electrician from Kummet Electric, earlier this week.  We finalized the lighting design & electrical layout. He should be starting his work in ~1 week.
4. Picking out the lighting fixutres is slowly progressing.  We still have several fixtures to pick out.
5. Crown Gas going to provide the temperary heater & a 500 gal LP gas tank to keep everybody warm on the construction site this winter.
6. Working on getting someone to keep the driveway clear to the jobsite this winter.
• See below for the reason why

 

Pop Quiz

Which vehicle left this "impression" in the snowbank after getting stuck?

1. Tom's truck
2. Nick's van
3. Joel's Subaru
4. Emily's Honda

Here's a clue:  Tom & Co pushed her out the first time & Nick's van pulled her out the second time!  Thanks for the help guys!

Day 126 - Framing is (almost) Done

Newsflash:  It's still really cold outside.  -18 F on the drive into work today.  Today Tom finished framing up the basement walls.  Emily & I just need to let him know where we wan the towel bars, so he can get extra bracing put in those areas.

The plan is for Brian from Albany Heating & Nick from Hoffman plumbing start their rough-in work next week.

This Friday Gered from G&E Cabinetry is coming up from Spencer, IA to measure for the cabinets.  Woohoo!  Good times.

The exciting news around the construction site today was that Harry decided it would be fun to stick his tongue on the metal construction lift that was sitting outside of the house.  He ripped off the skin from his tongue & came running to Emily with blood going everywhere.  A little bit of snow on the tongue & everything was good as new.  I couldn't be more proud that A Christmas Story came true in my family this year.  Now all Harry needs is a Red Rider BB gun!!!

Any way that about all.  No new pictures today of the house.  With it getting dark so early, I only get to the site after it's dark.  Here's a picture of the tub we're putting into the master bathroon.

Yep, it's blue!

My grandma would be so proud.  Her bathroom used to have a blue tub & toilet.  The answer to your question is no, the toilet is going to be white.  Now get your mind out of the toilet!  Sheesh :-)

Day 121 - Baby It's Cold Outside

125,000 BTU/hr of Tropical Delight

Cold as in -16 F as I type this!!!  Yeah, just a bit chilly.  However, thanks to Mr. Heater, Tom, Travis & Al were able to stay toasty warm & keep working today (OK, toasty may be a bit of an exaggeration).  The 2nd floor is completely framed in.  It looks like a jungle of 2x4's upstairs. 

Welcome to the Jungle

The kid's bedrooms are going to look really cool with their sloped ceilings & shelves above the closets.  We're also going to have an extra shelf by the vault in the master bedroom.  I'm not exactly sure what we'll put up there, but that's what nick knacks are for, right?  Just don't ask me to dust!  :-)

Kid's Bedroom Closet & Vault

The Master closest will have a 2nd doorway in it that leads to another storage space.  Normally this would be all unfinished attic space, but due to the SIPs, we can use it as heated storage.  Pretty cool.

It's a closet within a closet!

The mudroom staircase leading above the garage has also been framed in.  They had to move the door to the top of the stairs & build a platform at the bottom to make things fit correctly (Another necessary tweak due to the SIPs).

Don't they look inviting?

There will be a set of lockers up against the side of the stairs to unload all of our junk as we come into the house.  With the stairs in place, Emily is a bit concerned that the Mudroom will feel cramped with 5 people trying to put away winter clothes at the same time.  Personally, I think it will be great.  However, if Emily ends up giving me that "I told you so look" when everything is finished, it won't be the first or last time!

In other news, Extreme Panel shot me an email this past week asking for some pictures.  They want to use a picture of our house in their new brochures.  Pretty cool, eh?

Have a great weekend & stay warm!

Day 118 - Let it Snow!

Winter Wonderland

 Winter has officially arrived in central Minnesota.  Several inches of snow yesterday with more to come today.  By Friday the high is supposed to be -1 with a low of -16.  Brr... 

Despite all the inclement weather, the front porch got framed up yesterday.  Once it gets the sheeting on, then we should be able to finally finish the shingles.  After that, I'm hopeful that getting the windows in and the housewrap on will go fairly quick.

I want to give a big thank you to my neighbor, Mike.  He randomly came over to our house last night with his riding snow thrower and cleared my driveway!  The best thing about it?  He was driving his snow thrower with loafers on!  A true Minnesotan :-)  THANKS, Mike! 

Anyway, enjoy all the snow!

Mmm....Snow...

Day 117 - Front Porch, Appliances & Impulse Shopping on Black Friday

Front Porch

Tom & his crew started framing up the front porch this past Friday.  It was a little bit chilly outside. As they started to place the trusses for the porch ceiling, they came across another glitch.  The trusses came right up to the bottom of the master bedroom window leaving no room for flashing/window trim/shingles! Oops. When we converted the house to SIPs & added the 2nd layer of roof decking, the porch trusses became too tall.   The solution was to drop the porch ceiling height 6 inches. Good thing Linus isn't a tall kid :-)

In other news, we took advantage of some great Black Friday deals over the weekend & bought all of our appliances online.  We had a local appliance store give us a quote, but ultimately we saved a bunch of money buying online.  Savings on state sales tax alone was like getting the dishwasher for free!  We also stopped by Menard's on a whim & bought a faucet for the main floor bathroom.  You know that you're building a new house when your impulse purchase is to buy a bathroom faucet!

 

 

Emily & Harry chillin' at the job site.  Literally chillin' because it was COLD outside last Friday!

 

In other news, Christmas has come to the current Dunn house:

 

Christmas decorations going up!